Miller Electric Welding System OM 4409 User Manual

OM-4409

206 941V

2007−05

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)

Cutting and Gouging

With Optional Equipment:

Battery Charging

Description

Engine Driven Welding Generator And

Air Compressor

Big Blue Air Pak

File: Engine Drive

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .

2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-2. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-3. Sound Level T a ble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-4. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4-5. Stick And MIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-6. TIG Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-7. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-8. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-9. Generator AC Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4-10. Optional 3-Phase Generator Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4-1 1 . Air Compressor Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4-12. Optional Battery Charging Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4-13. Manufacturing Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-3. Installing Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-6. Using The Optional Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-7. Engine/Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5-8. Connecting T o Weld Output T e rminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5-10. Connecting T o R emote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5-1 1 . Connecting T o T he Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 6 − OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-1. Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-2. Description Of Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6-4. Using Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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TABLE OF CONTENTS

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7-2. Connecting T o O ptional AC Power Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7-3. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8-1. Battery Charge Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8-2. Determining Battery Charging Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8-3. Battery Charge Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8-4. Battery Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8-5. Jump Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SECTION 9 − ENGINE/GENERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9-1. Engine Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

9-2. Routine Engine/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

9-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

9-4. Servicing Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

9-5. Inspecting/Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9-6. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

9-7. Servicing Engine Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9-8. Engine/Generator Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

SECTION 10 − AIR COMPRESSOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

10-1. Air Compressor Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

10-2. Routine Air Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10-3. Servicing Compressor Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10-4. Compressor Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

10-5. Servicing Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

10-6. Adjusting Compressor Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SECTION 11 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

11-1. Troubleshooting T a bles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SECTION 12 − AIR COMPRESSOR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

SECTION 13 − CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

SECTION 14 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

14-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

14-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

14-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

SECTION 15 − AIR COMPRESSOR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

15-2. Approximate Air Consumption (Cubic Feet) T o O perate Pneumatic Equipment At 70-90 P .S.I.G. . . . 68

SECTION 16 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

SECTION 17 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING . . . . . . . . . . . . . 76

17-1. Selecting Tungsten Electrode (Wear Clean gloves T o P revent Contamination Of Tungsten ). . . . . . . . 7 6

17-2. Preparing Tungsten Electrode For Welding With Phase Control Machines . . . . . . . . . . . . . . . . . . . . . . 76

SECTION 18 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

18-1. Positioning The T o rch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

18-2. T o rch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

18-3. Positioning T o rch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SECTION 19 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

WARRANTY

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

Always verify the supply ground — check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

groundedreceptacle outlet.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

Frequentlyinspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

Turn off all equipment when not in use.

Do not use worn, damaged, undersized, or poorly spliced cables.

Do not drape cables over your body.

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-7. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

ELECTRIC SHOCK can kill.

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Touching live electrical parts can cause fatal shocks or

severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also live when power is

on. In semiautomatic or automatic wire welding, the wire, wire reel,

drive roll housing, and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly grounded equip-

ment is a hazard.

Do not touch live electrical parts.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

Do not connect more than one electrode or work cable to any

single weld output terminal.

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

Use AC output ONLY if required for the welding process.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

If AC output is required, use remote output control if present on

unit.

Additionalsafety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomaticDC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

Wear approved safety glasses with side shields even under your

welding helmet.

Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

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Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire haz-

ards.

If ventilation is poor, wear an approved air-supplied respirator.

Do not use welder to thaw frozen pipes.

Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or

cadmiumplated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can dam-

age hearing.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

ARC RAYS can burn eyes and skin.

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Sparks fly off from the weld.

ImplantedMedical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

Wear an approved welding helmet fitted with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks

when welding or watching (see ANSI Z49.1 and Z87.1 listed in

Safety Standards).

Wear approved safety glasses with side shields under your

helmet.

Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres-

sure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process, be

sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

WELDING can cause fire or explosion.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Welding on closed containers, such as tanks, drums,

or pipes, can cause them to blow up. Sparks can fly off

from the welding arc. The flying sparks, hot workpiece,

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

and hot equipment can cause fires and burns. Accidental contact of

electrodeto metal objects can cause sparks, explosion, overheating,

or fire. Check and be sure the area is safe before doing any welding.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

Turn face away from valve outlet when opening cylinder valve.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Watch for fire, and keep a fire extinguisher nearby.

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

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1-3. Engine Hazards

STEAM AND HOT COOLANT can burn.

BATTERY EXPLOSION can BLIND.

If possible, check coolant level when engine is

cold to avoid scalding.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

Do not allow tools to cause sparks when working on a battery.

Do not use welder to charge batteries or jump start vehicles.

Observe correct polarity (+ and −) on batteries.

If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

Disconnect negative (−) cable first and connect it last.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before

completely removing cap.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or

adding fuel.

Do not add fuel while smoking or if unit is near

any sparks or open flames.

Using a generator indoors CAN KILL

YOU IN MINUTES.

Do not overfill tank — allow room for fuel to expand.

Do not spill fuel. If fuel is spilled, clean up before starting engine.

Dispose of rags in a fireproof container.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Always keep nozzle in contact with tank when fueling.

NEVER use inside a home or garage, EVEN IF

doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and

vents.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

BATTERY ACID can BURN SKIN and EYES.

Stop engine before installing or connecting unit.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

Have only qualified people remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

Keep hands, hair, loose clothing, and tools away from moving

parts.

ENGINE HEAT can cause fire.

Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

Do not locate unit on, over, or near combustible

surfaces or flammables.

Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

Keep exhaust and exhaust pipes way from

flammables.

Block flywheel so that it will not turn while working on generator

components.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

1-4. Compressed Air Hazards

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

BREATHING COMPRESSED AIR can

cause serious injury or death.

Release air pressure from tools and system be-

fore servicing, adding or changing attach-

ments, or opening compressor oil drain or oil fill

cap.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

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HOT METAL from air arc cutting and

gouging can cause fire or explosion.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Stop engine and release air pressure before

servicing.

Use only genuine replacement parts from the

manufacturer.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air system

parts.

Let system cool down before touching or ser-

vicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

WELDING WIRE can cause injury.

Do not install or place unit on, over, or near

combustiblesurfaces.

Do not press gun trigger until instructed to do

so.

Do not install unit near flammables.

Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING.

Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not

exceed maximum lift eye weight rating (see

Specifications).

Lift and support unit only with proper equipment

and correct procedures.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

Do not block or filter airflow to unit.

If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

OVERHEATING can damage motors.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

Turn off or unplug equipment before starting or

stopping engine.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

TILTING OF TRAILER can cause injury.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Use only genuine replacement parts from the

manufacturer.

Perform engine and air compressor mainte-

nance and service according to this manual

and the engine/air compressor (if applicable)

manuals.

Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

Keep away from moving parts.

Keep away from pinch points such as drive

rolls.

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H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

Electromagnetic energy can interfere with

sensitive electronic equipment such as micro-

processors, computers, and computer-driven

equipmentsuch as robots.

Be sure all equipment in the welding area is

electromagneticallycompatible.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

If notified by the FCC about interference, stop using the

equipmentat once.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Have the installation regularly checked and maintained.

Be sure this welding machine is installed and grounded

according to this manual.

Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-6. California Proposition 65 Warnings

For Gasoline Engines:

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductiveharm. Wash hands after handling.

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-7. Principal Safety Standards

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from Global Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044,website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:

212-642-4900,website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-

site: www.nfpa.org.

Recommended Safe Practices for the Preparation for Weldingand Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:

1-877-413-5184,website: www.global.ihs.com).

NationalElectrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:

617-770-3000,website: www.nfpa.org and www. sparky.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

CanadianStandards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from

operator as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined.Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

About Implanted Medical Devices:

ImplantedMedical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

To reduce magnetic fields in the workplace, use the following

procedures:

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on

l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles

joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas

peut donner la mort ou des blessures graves. Les dan-

gers possibles sont montrés par les symboles joints ou

sont expliqués dans le texte.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Consulter les symboles et les instructions ci-dessous y

afférant pour les actions nécessaires afin d’éviter le danger.

NOTE − Indique des déclarations pas en relation avec des blessures

personnelles.

2-2. Dangers relatifs au soudage à l’arc

manuelAC avec tension à vide réduite. Dans la plupart des cas, un

poste courant continu de type CV est recommandé. Et, ne pas tra-

vailler seul!

Couper l’alimentation ou arrêter le moteur avant de procéder à

l’installation, à la réparation ou à l’entretien de l’appareil.

Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147(voir normes de sécurité).

Installer et mettre à la terre correctement cet appareil conformé-

ment à son manuel d’utilisation et aux codes nationaux,

provinciaux et municipaux.

Toujours vérifier la terre du cordon d’alimentation − Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien

raccordé à la borne de terre du sectionneur ou que la fiche du

cordon est raccordée à une prise correctement mise à la terre.

En effectuant les raccordements d’entrée fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau-

des.

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

pas endommagé ou dénudé − remplacer le cordon immédiatement

s’il est endommagé − un câble dénudé peut provoquer une électro-

cution.

Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées à la section 2-7. Veuillez lire et respecter

toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne

doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus

particulièrementles enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquerune électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension

dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

internes de l’appareil sont également sous tension à ce moment-là.

En soudage semi-automatique ou automatique, le fil, le dévidoir, le

logement des galets d’entraînement et les pièces métalliques en

contact avec le fil de soudage sont sous tension. Des matériels mal

installés ou mal mis à la terre présentent un danger.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

Ne pas enrouler les câbles autour du corps.

Ne jamais toucher les pièces électriques sous tension.

Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct − ne pas utiliser le connecteur de pièce ou le

câble de retour.

Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-

blée.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil

conformémentà ce manuel.

Porter un harnais de sécurité quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près

possible de la soudure.

Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact

physique éventuel avec la pièce ou la terre.

Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de

tomber.

Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil

en est équipé.

Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou

lorsque l’on porte des vêtements mouillés; sur des structures mé-

talliques au sol, grillages et échafaudages; dans des positions

assises, à genoux et allongées; ou quand il y a un risque important

de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser

les appareils suivants dans l’ordre de préférence: 1) un poste à

souder DC semi−automatique de type CV (MIG/MAG), 2) un poste

à souder manuel (électrode enrobée) DC, 3) un poste à souder

Une tension DC importante subsiste à l’intérieur

des onduleurs après avoir coupé l’alimentation.

Couper l’alimentation du poste et décharger les condensateurs

d’entrée comme indiqué dans la Section Maintenance avant de

toucher des composants.

OM-4409 Page 6

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Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage

(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements

et les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de

protection.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites peu

provoquer leur éclatement. Des étincelles peuven

Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules

métalliquesvolantes. Pendant la période de refroidissement des

soudures, elles risquent de projeter du laitier.

être projetées de l’arc de soudure. La projection d’étincelles, des pièce

chaudes et des équipements chauds peut provoquer des incendies e

des brûlures. Le contact accidentel de l’électrode avec des objet

métalliquespeut provoquer des étincelles, une explosion, un surchauf

fement ou un incendie. Avant de commencer le soudage, vérifier e

s’assurer que l’endroit ne présente pas de danger.

Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent être

dangereux.

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir

soigneusementavec des protections homologués.

Le soudage génère des fumées et des gaz. Leur

inhalationpeut être dangereux pour votre santé.

Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.

Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les

consommables, les revêtements, les nettoyants et les dégraisseurs.

Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à

un surveillant dûment formé de se tenir à proximité. Des fumées et

des gaz de soudage peuvent déplacer l’air et abaisser le niveau

d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été

préparés correctement conformément à AWS F4.1 (voir les nor-

mes de sécurité).

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une

longue distance par des chemins inconnus éventuels en provo-

quant des risques d’électrocution, d’étincelles et d’incendie.

Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et

les rayons de l’arc peuvent réagir en présence de vapeurs et for-

mer des gaz hautement toxiques et irritants.

Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête-

ment n’ait été enlevé dans la zone de soudure, que l’endroit soit

bien ventilé, et en portant un respirateur à alimentation d’air. Les

revêtementset tous les métaux renfermant ces éléments peuvent

dégager des fumées toxiques en cas de soudage.

Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans

revers, des chaussures hautes et un couvre chef.

LES ACCUMULATIONS DE GAZ ris

quent de provoquer des blessures ou

même la mort.

Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateurd’adduction d’air homologué.

Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un

extincteur à proximité.

LES RAYONS DE L’ARC peuvent pro

voquer des brûlures dans les yeux e

sur la peau.

LE BRUIT peut affecter l’ouïe.

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure

dans les yeux et sur la peau. Des étincelles sont projetées pendant le

soudage.

Le bruit des processus et des équipements peut affec

l’ouïe.

Porter des protections approuvés pour les ore

les si le niveau sonore est trop élevé.

OM-4409 Page 7

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Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou

de se renverser.

LES CHAMPS MAGNETIQUES peuv-

ent affecter des implants médicaux.

Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou-

dage par points, de gougeage, du coupage plasma ou de chauf-

fage par induction.

Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

Ne jamais souder une bouteille pressurisée − risque d’explosion.

Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;

les maintenir ainsi que les éléments associés en bon état.

Si des BOUTEILLES sont endomma

gées, elles pourront exploser.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

Des bouteilles de gaz protecteur contiennent du ga

sous haute pression. Si une bouteille est endomma

Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisationou de branchement de la bouteille.

gée, elle peut exploser. Du fait que les bouteilles de gaz fon

normalement partie du procédé de soudage, les manipuler ave

précaution.

Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des

flammes ouvertes, des étincelles et des arcs.

Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas

Association) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour

effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

L’EXPLOSION DE LA BATTERIE peu

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants

en caoutchouc et vêtements de protection lors

d’une intervention sur la batterie.

Pour empêcher tout démarrage accidentel pendant les travaux

d’entretien,débrancher le câble négatif (−) de batterie de la borne.

Ne pas approcher les mains, cheveux, vêtements lâches et outils

des organes mobiles.

Arrêter le moteur avant de débrancher ou de brancher les câbles

de batterie.

Remettreen place les panneaux ou les dispositifs de protection et

fermer les portes à la fin des travaux d’entretien et avant de faire

démarrer le moteur.

Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la

mise en route accidentelle du moteur.

Ne pas utiliser le poste de soudage pour charger les batteries ou

des véhicules de démarrage rapide.

Bloquerle volant moteur pour éviter sa rotation lors d’une interven-

tion sur le générateur.

Observer la polarité correcte (+ et −) sur les batteries.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

LE CARBURANT MOTEUR peut provo

quer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau de

carburant ou de faire le plein.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

Ne pas faire le plein en fumant ou proche d’une source d’étincelles

ou d’une flamme nue.

Ne pas faire le plein de carburant à ras bord; prévoir de l’espace

pour son expansion.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Faire attention de ne pas renverser de carburant. Nettoyer tout

carburant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

Il est préférable de vérifier le liquide de refroi-

dissementune fois le moteur refroidi pour éviter

de se brûler.

Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré-

cisé autrement dans la section maintenance du manuel du

moteur).

DES ORGANES MOBILES peuvent pro

voquer des blessures.

Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

Ne pas approcher les mains des ventilateurs,

courroies et autres pièces en mouvement.

Mettre des lunettes de sécurité et des gants, placer un torchon sur

le bouchon du radiateur.

Maintenirfermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

Arrêter le moteur avant d’installer ou brancher l’appareil.

OM-4409 Page 8

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L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN

QUELQUES MINUTES.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces inflammables.

Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi-

ble et inodore.

Tenir à distance les produits inflammables de l’échappement.

JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

Rincer immédiatement les yeux et la peau à l’eau.

2-4. Dangers liés à l’air comprimé

Le METAL CHAUD lors du coupage et

gougeage plasma peut provoquer un in-

cendie ou une explosion.

RESPIRER L’AIR COMPRIMÉ peut pro-

voquer des blessures graves ou causer

la mort.

Ne pas couper ou gouger à proximité de pro-

duits inflammables.

Surveillez et garder un extincteur à proximité.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou

soi-même.

Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la

maintenance.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer des blessures.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

Relâcher la pression d’air de l’outillage ou du

système avant d’effectuer la maintenance,

avant de changer ou de rajouter des éléments

ou avant d’ouvrir la purge ou le bouchon de

remplissaged’huile.

Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

N’utiliser que les pièces de rechange recommandées par le

constructeur.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO-

SION.

LA CHUTE DE L’APPAREIL peut blesser.

Utiliser l’anneau de levage pour lever l’appareil et

les accessoires correctement installées seuls,

PAS les bouteilles de gaz. Ne pas dépasser le

poids nominal maximal de l’œilleton (voir les spé-

cifications).

Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

Ne pas installer l’appareil à proximité de pro-

duits inflammables.

Ne lever et ne soutenir l’appareil qu’avec de

l’équipement approprié et en suivant les

procédures adéquates.

Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentationest correctement dimensionnée et protégée avant de

mettre l’appareil en service.

En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du

côté opposé de l’appareil.

OM-4409 Page 9

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UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

Arrêter ou déconnecter l’équipement avant de

démarrer ou d’arrêter le moteur.

Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor-

tant.

Ne pas laisser tourner le moteur trop lentement sous risque d’en-

dommagerle moteur électrique à cause d’une tension et d’une fré-

quence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,

s’il y a lieu.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Effectuer la maintenance et le service du moteur et du compres-

seur d’air suivant les instructions dans ce manuel ou le manuel

du moteur/compresseur (si applicable).

Porter un écran facial pour protéger le visage et

les yeux.

Affûter l’électrode au tungstène uniquement à la

meuleuse dotée de protecteurs. Cette manœuv-

re est à exécuter dans un endroit sûr lorsque l’on

porte l’équipement homologué de protection du

visage, des mains et du corps.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe-

ments de radio−navigation et de communica-

tion, les services de sécurité et les ordinateurs.

Les étincelles risquent de causer un incendie − éloigner toute sub-

stance inflammable.

Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal-

lation.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas s’approcher des organes mobiles.

Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

L’utilisateurest tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

Maintenirsoigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis-

tance correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga-

geant le fil de soudage.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec-

tronique sensible tel que les ordinateurs et

l’équipementcommandé par ordinateur tel que

les robots.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

Veiller à ce que tout l’équipement de la zone de soudage soit

compatibleélectromagnétiquement.

Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

Ne pas obstruer les passages d’air du poste.

Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentairestelles que le déplacement du poste, l’utilisation de câ-

bles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

OM-4409 Page 10

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2-6. Proposition californienne 65 Avertissements

Pour les moteurs à essence :

Les équipements de soudage et de coupage produisent des

fumées et des gaz qui contiennent des produits chimiques

dont l’État de Californie reconnaît qu’ils provoquent des mal-

formations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

Les gaz d’échappement des moteurs contiennent des pro-

duits chimiques dont l’État de Californie reconnaît qu’ils

provoquent des cancers et des malformations congénitales

ou autres problèmes de procréation.

Pour les moteurs diesel :

Les batteries, les bornes et autres accessoires contiennent

du plomb et des composés à base de plomb, produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des

cancers et des malformations congénitales ou autres

problèmesde procréation. Se laver les mains après manipu-

lation.

Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie com-

me provoquant des cancers et des malformations

congénitalesou autres problèmes de procréation.

2-7. Principales normes de sécurité

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site

Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :

212-642-4900,site Internet : www.ansi.org).

RecommendedSafe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone

1-877-413-5184,site Internet : www.global.ihs.com).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,

site Internet : www.nfpa.org).

National Electrical Code, NFPA Standard 70, de National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-

ne de la région 5, Chicago, est 312-353-2220, site Internet :

www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-

tilly, VA 20151 (téléphone

www.cganet.com).

703-788-2700, site Internet

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

CanadianStandards Association, 5060 Mississauga, Ontario, Canada

2-8. Information EMF

Considérationssur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

1. Garder les câbles ensemble, les torsader, les scotcher, ou les

recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir exa-

miné plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National

Research Council a conclu : « L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiqueset champs électriques à haute fréquence représente un

risque à la santé humaine ». Toutefois, des études sont toujours en

cours et les preuves continuent à être examinées. En attendant que les

conclusions finales de la recherche soient établies, il vous serait

souhaitablede réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

4. Garder le poste de soudage et les câbles le plus loin possible de

vous.

5. Connecter la pince sur la pièce aussi près que possible de la

soudure.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

Pour réduire les champs magnétiques sur le poste de travail, appliquer

les procédures suivantes :

OM-4409 Page 11

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SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Fast (Run, Weld/

Power)

Stop Engine

Slow (Idle)

Starting Aid

Start Engine

Engine

Check engine belt

Check Air Cleaner

Jump start/Battery

Charge

Battery (Engine)

Battery Charge

Jump Start

Engine Oil

OPT

Do Not Switch

Under Load

Read Operator’s

Manual

Certified/Trained

Mechanic

Check Injectors/

Pump

Check Valve

Clearance

Engine Coolant

Temperature

Fuel

Hourmeter (HM)

Air Pressure

Temperature

Air Compressor

Positive

Negative

Volts

Wire Feed

Welding Arc

Remote

Amperes

Panel/Local

A V

Direct Current

(DC)

Alternating

Current (AC)

Gas Tungsten Arc

Welding (TIG)

Output

Stick (SMAW)

Welding

Constant Current

(CC)

MIG (GMAW)

Welding

Constant Voltage

(CV)

Air Carbon Arc

Cutting (CAC-A)

Protective Earth

(Ground)

Three Phase

Single Phase

DC Electrode

Positive

DC Electrode

Negative

Electrode

Work Connection

Hours

Connection

Circuit Protector

Time

Off

Seconds

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SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Maximum

Open-Circuit

Voltage

Weld

Output

Range

Rated

Welding

Output

Engine

Oil

Capacity

Welding

Mode

Generator Power

Rating

Fuel Tank

Capacity

Engine

(Nominal)

500 A,

40 Volts

DC,

100% Duty

Cycle

CC/DC

CV/DC

20 − 750 A

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC,

50/60 Hz

14 − 40 V

DEUTZ

600 A,

44 Volts

DC,

40% Duty

Cycle

Deutz BF4M2011

Oil-Cooled,

CC/AC

(Optional)

11 qt

(10.4 L)

25 gal

(95 L)

3-Phase Generator

Option*

Single-Phase/Three-Phase,

12/20 kVA/kW, 50/48A,

120/240 VAC, 60 Hz

20 - 575

12/24 V

Four-Cylinder,

Turbo-Charged

63.4 HP Diesel Engine

750 A,

12 Volt

Jump Start

Battery

Charge/

Jump

*In Addition To Standard

4 kVA/kW Generator Power

14/28

750 A,

24 Volt

Jump Start

Start

4-2. Air Compressor Specifications

Compressor Model

And Type

Air Output At Effective

Working Pressure

Factory Pressure

Setting

Safety Relief

Valve Rating

Air Compressor

Oil Capacity

−1

60 scfm (1.7 m min ),

100 psi (690 kPa),

100% Duty Cycle

Ingersoll Rand CE55 G

Rotary Screw

125 psi (862 kPa)

150 psi (1034 kPa)

4 qt (3.8 L)

4-3. Sound Level Table

Weld/Power Speed

(1850 rpm)

40 Volts DC At 500

Amps

44 Volts DC At 600

Amps

Idle Speed (1235 rpm)

96.6 Lwa sound power

102.8 Lwa sound power

103.9 Lwa sound power

106.0 Lwa sound power

71.7 dBa at 23 ft (7 m)

77.2 dBA 3.3 ft (1 m)

from front panel

77.9 dBa at 23 ft (7 m)

83.0 dBA 3.3 ft (1 m)

from front panel

79.0 dBa at 23 ft ( 7 m)

89.8 dBA 3.3 ft (1 m)

from front panel

81.1 dBa at 23 ft (7 m)

93.3 dBA 3.3 ft (1 m)

from front panel

Air Compressor On

Air Compressor Off

94.6 Lwa sound power

100.6 Lwa sound power

103.0 Lwa sound power

104.5 Lwa sound power

69.7 dBa at 23 ft (7 m)

74.5 dBA 3.3 ft (1 m)

from front panel

75.7dBa at 23 ft (7 m)

78.8 dBA 3.3 ft (1 m)

from front panel

78.1dBa at 23 ft (7 m)

86.0 dBA 3.3 ft (1 m)

from front panel

79.6 dBa at 23 ft (7 m)

91.8 dBA 3.3 ft (1 m)

from front panel

OM-4409 Page 13

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4-4. Dimensions, Weights, And Operating Angles

Dimensions

54-1/2 in (1384 mm)

Height

(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)

Width

Do not exceed tilt angles or engine could

be damaged or unit could tip.

30-3/4 in (781 mm)

(mtg. brackets turned out)

Do not move or operate unit where it could

tip.

Depth

69-1/2 in (1765 mm)

55-7/8 in (1419 mm)

46-3/8 in (1178)

11 in (279 mm)

27-1/2 in (699 mm)

1 in (25 mm)

30°

29-13/16in (757 mm)

30°

9/16 in (14 mm) Dia.

4 Holes

20°

Front Panel End

With mounting brackets in center

position. Dimensions vary with loca-

tion of mounting brackets.

Weight

No fuel: 2010 lb (907 kg)

w/fuel: 2185 lb (993 kg)

802 161-A

803 231

Lifting Eye Weight Rating

2185 lb (993 kg) Maximum

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4409 Page 14

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4-5. Stick And MIG Volt-Ampere Curves

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

A. DC Stick Mode

100

Ranges

300 − Max

185 − 525

125 − 400

85 − 250

55 − 125

100 200 300 400 500 600 700 800 900 1000

DC AMPERES

B. AC Stick Mode (Optional)

100

200

300

400

500

600

700

AC AMPERES

C. MIG Mode

100

MAX

MIN

100 200 300 400 500 600 700 800 900 1000

DC AMPERES

208 135 / 203 415 / 208 956

OM-4409 Page 15

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4-6. TIG Volt-Ampere Curves

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities of

the welding generator. Curves of all

other settings fall between the

curves shown.

A. DC TIG Mode

100

Ranges

60−450

40−330

30−220

20−110

50 100 150 200 250 300 350 400 450 500 550 600 650 700

DC AMPERES

B. AC TIG Mode (Optional)

100

200

300

400

500

600

700

AC AMPERES

208 136 / 208 957

OM-4409 Page 16

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4-7. Fuel Consumption

The curve shows typical fuel use

under weld or generator power

loads.

3.00

2.75

2.50

2.25

2.00

1.75

1.50

1.25

1.00

0.75

w/ Air Output

0.50

IDLE

0.25

0.00

100 150 200 250 300 350 400 450 500 550 600

DC WELD AMPERES AT 100% DUTY CYCLE

208 211

4-8. Duty Cycle And Overheating

100% Duty Cycle At 500 Amperes

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

ContinuousWelding

40% Duty Cycle At 600 Amperes

4 Minutes Welding

6 Minutes Resting

1000

800

600

500

400

300

250

200

150

100

25 30

40 50 60

100

% DUTY CYCLE

202 356

OM-4409 Page 17

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4-9. Generator AC Power Curve

The ac power curve shows the gen-

erator power in amperes available

at the 120 and 240 volt receptacles.

150 300

125 250

100 200

75 150

50 100

AC AMPERES IN 240V MODE

20 30 40

AC AMPERES IN 120V MODE

193 018

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4409 Page 18

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4-10. Optional 3-Phase Generator Power Curves

The ac power curves show the gen-

erator power available in amperes

at the single-phase 120/240 volt re-

ceptacle or three-phase 240 volt

terminals.

A. 12 kVA/kW Single-Phase AC Output (No Weld Load)

280

270

260

250

240

230

220

210

200

190

180

140

135

130

125

120

115

110

105

100

AC AMPERES

B. 20 kVA/kW Three-Phase AC Output (No Weld Load)

280

260

240

220

200

180

AC AMPERES

197 472 / 197 473

OM-4409 Page 19

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4-11. Air Compressor Output Curve

The air output curve shows the vol-

ume and pressure of air available

from the air compressor.

140

120

100

Idle

100

CUBIC FEET PER MINUTE (CFM)

208 955

4-12. Optional Battery Charging Output Curve

The battery charging curves show

the charging amperage and voltage

output of the welding generator.

As battery voltage nears the charg-

ing voltage, charging current de-

creases.

100 200 300 400 500 600 700 800 900 1000

DC AMPERES

210 269

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4-13. Manufacturing Rating Label

OM-4409 Page 21

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SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Always securely fasten weld-

ing generator onto transport

vehicle or trailer and comply

with all DOT and other applica-

ble codes.

Movement

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

If unit does not have GFCI re-

ceptacles,use GFCI-protected

extension cord.

NOTICE − Do not install unit where

air flow is restricted or engine may

overheat.

Location/AirflowClearance

ing.

formation.

Grounding:

Equipment Grounding Terminal

(On Front Panel)

Grounding Cable (Not Supplied)

Metal Vehicle Frame

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger insu-

lated copper wire.

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Grounding

GND/PE

Electrically bond generator frame to

vehicle frame by metal-to-metal contact.

Bed liners, shipping skids, and some running

gears insulate the welding generator from the

vehicle frame. Always connect a ground wire

from the generator equipment grounding termi-

nal to bare metal on the vehicle frame as shown.

install3 8/06 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-4409 Page 22

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5-2. Mounting Welding Generator

Do not weld on base. Weld-

ing on base can cause fuel

tank fire or explosion. Weld

only on the four mounting

brackets or bolt unit down.

Supporting The Unit

Do not mount unit by sup-

porting the base only at the

four

mounting brackets.

Use cross-supports to ade-

quately support unit and pre-

vent damage to base.

Mounting Surface:

Cross-Supports

Mounting Brackets (Supplied)

Mount unit on flat surface or use

cross-supports to support base.

Secure unit with mounting brack-

ets.

1/2 in Bolt And Washer

(Minimum − Not Supplied)

Inadequate support.

3/8-16 x 1 in Screws

(Supplied)

Do not use flexible mounts.

To Bolt Unit In Place:

Remove hardware securing the

four mounting brackets to the base.

Reverse brackets and reattach to

base with original hardware.

Using Mounting Brackets

Mount unit to truck or trailer with 1/2

in (12 mm) or larger hardware (not

supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at

the four mounting brackets.

Welding Unit In Place

Bolting Unit In Place

Tools Needed:

9/16 in

install3 8/06 803 274 / 200 864-A / 803 602

OM-4409 Page 23

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5-3. Installing Optional Spark Arrestor Muffler

Stop engine and let cool.

Spark Arrestor Muffler

Double-Flanged Elbow

Nut

Flat Washer

Mount

Bracket

Screw

Single-Flanged Elbow

Rain Cap

10 Clamp

Loosely assemble components as

shown.

out plug to the outside.

After assembly, final-tighten all

clamps and hardware.

mountingscrew.

Tools Needed:

7/16, 1/2 in

803 230

OM-4409 Page 24

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5-4. Activating The Dry Charge Battery (If Applicable)

Always wear a face shield,

rubber gloves and protective

clothing when working on a

battery.

Remove battery from unit.

Vent Caps

Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

Well

Fill each cell with electrolyte to

bottom of well (maximum).

Do not overfill battery cells.

Wait ten minutes and check electro-

lyte level. If necessary, add electro-

lyte to raise to proper level. Reins-

tall vent caps.

Battery Charger

Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30

amperes or 30 minutes at 5 am-

peres. Disconnect charging cables

and install battery.

. When electrolyte is low, add

only distilled water to cells to

maintainproper level.

5 A For 30 Minutes

−

30 A For 12 Minutes

Tools Needed:

drybatt1 6/05 − S-0886

5-5. Connecting The Battery

Connect Negative (−) Cable Last.

−

Tools Needed:

1/2 in

802 168-E / Ref. 202 705 / 802 313 / S-0756-C

OM-4409 Page 25

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5-6. Using The Optional Battery Disconnect Switch

Stop engine.

Battery Disconnect Switch

The battery disconnect switch dis-

connects battery voltage from the

circuit. When the switch is turned

Off, the front panel controls do not

work.

OFF

To run unit, turn switch to On posi-

tion. To prevent unit from running,

turn switch to Off position.

The switch may be locked using a

customer-suppliedpadlock.

803 228 / Ref. 803 324

Notes

Start Your Professional

Over 80,000 trained

since 1930!

400 Trade Square East, Troy, Ohio 45373

1-800-332-9448 www.welding.org

Welding Career Now!

OM-4409 Page 26

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5-7. Engine/Compressor Prestart Checks

Engine Oil

Compressor

Oil

Full

Diesel

Too

High

Full

Too

Low

Full

803 228

Add fresh diesel fuel before starting to pre-

vent air from entering the fuel system (see

enginemaintenance label for fuel specifica-

tions). Leave filler neck empty to allow room

for expansion.

if oil is not up to full mark on indicator (see

maintenance label for oil specifications).

daily.

Engine must be cold and on a level surface.

Unit is shipped with 20W break-in oil. The

automaticshutdown system stops engine if

oil pressure is too low or coolant tempera-

ture is too high.

Cold Weather Starting

Engine stops if fuel level is low on units with

low fuel shutdown option. Do not run out of

fuel or air may enter fuel system and cause

starting problems. See engine manual to

bleed air from fuel system.

Use Starting Aid switch (see Section

6-1).

down switch. However, some condi-

tions may cause engine damage before

the engine shuts down. Check oil level

often and do not use the oil pressure

shutdown system to monitor oil level.

Engine Oil

Keep battery in good condition. Store

battery in warm area.

After fueling, check oil with unit on level sur-

face. If oil is not up to full mark on dipstick,

add oil (see maintenance label for engine oil

specifications).

Use fuel formulated for cold weather

(diesel fuel can gel in cold weather).

Contact local fuel supplier for fuel in-

formation.

Follow run-in procedure in engine manual.

If unburned fuel and oil collect in exhaust

pipe during run-in, see Section 14.

Compressor Oil

Compressor Oil Level Indicator (On

Tank)

Fuel

Use correct grade oil for cold weather

(see Section 9-1).

NOTICE − Do not use gasoline. Gasoline

will damage engine.

Check oil with unit on level surface. Add oil

OM-4409 Page 27

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5-8. Connecting To Weld Output Terminals

Stick And TIG Welding

MIG And FCAW Welding

For Stick welding Direct Current Electrode

For MIG welding Direct Current Electrode

Positive (DCEP), connect wire feeder

cable to Positive (+) terminal on left and

work cable to Negative (−) terminal on

right. Use Process/Contactor switch to

select type of weld output (see Section

6-3).

Positive (DCEP), connect electrode hold-

er cable to Positive (+) terminal on left and

work cable to Negative (−) terminal on

right.

For Stick and TIG Direct Current Elec-

trode Negative (DCEN), connect elec-

trode holder cable to Negative (−) terminal

on right and work cable to Positive (+) ter-

minal on left.

For MIG and FCAW Direct Current Elec-

trode Negative (DCEN), connect wire

feeder cable to Negative (−) terminal on

right and work cable to Positive (+) termi-

nal on left. Use Process/Contactor switch

to select type of weld output (see Section

6-3).

If equipped with optional Polarity/AC Se-

lector switch, connect electrode holder

cable to Electrode terminal on left and

work cable to Work terminal on right.

Stop engine.

Positive (+) Weld Output Terminal

Negative (−) Weld Output Terminal

If equipped with optional Polarity/AC Se-

lector switch, connect wire feeder cable to

Electrode terminal on left and work cable

to Work terminal on right.

Failure to properly connect weld

cables may cause excessive heat and

start a fire, or damage your machine.

Weld Output Terminal

Supplied Weld Output Terminal Nut

Weld Cable Terminal

Copper Bar

Remove supplied nut from weld output termi-

nal. Slide weld cable terminal onto weld output

terminaland secure with nut so that weld cable

terminal is tight against copper bar. Do not

place anything between weld cable termi-

nal and copper bar. Make sure that the sur-

faces of the weld cable terminal and cop-

per bar are clean.

Tools Needed:

3/4 in

Do not place

anything between

weld cable terminal

and copper bar.

803 231 / 803 778-A

Correct Installation

Incorrect Installation

OM-4409 Page 28

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5-9. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

Weld Output

Terminals

Turn off power before

connecting to weld

output terminals.

150 ft

(45 m)

200 ft

250 ft

300 ft

350 ft

400 ft

100 ft (30 m) or Less

(60 m) (70 m) (90 m) (105 m) (120 m)

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

10 − 60% 60 − 100%

Welding

Amperes

Duty

10 − 100% Duty Cycle

Cycle

100

150

200

4 (20)

3 (30)

4 (20)

3 (30)

2 (35)

4 (20)

2 (35)

1 (50)

3 (30)

1 (50)

2 (35)

1/0 (60)

2/0 (70)

1 (50)

1/0 (60)

3/0 (95)

1/0 (60)

3/0 (95)

2/0 (70)

1/0 (60)

3/0 (95) 4/0 (120) 4/0 (120)

2 ea. 2/0 2 ea. 2/0

250

300

350

2 (35)

1 (50)

1/0 (60)

2/0 (70)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2/0 (70)

3/0 (95) 4/0 (120)

(2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

(2x70) (2x95) (2x95)

3/0 (95) 4/0 (120)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0

(2x70) (2x95) (2x95) (2x120)

1/0 (60)

4/0 (120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0

(2x70) (2x95) (2x120) (2x120)

400

500

600

700

800

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2/0 (70)

3/0 (95)

4/0 (120)

2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0

(2x70) (2x95) (2x120) (3x95) (3x95)

2 ea. 2/0

(2x70)

2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0

(2x95) (2x120) (3x95) (3x120) (3x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0 3 ea. 3/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0

(2x120) (3x95) (3x120) (3x120) (4x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0 3 ea. 4/0 3 ea. 4/0 4 ea. 4/0 4 ea. 4/0

(2x120)

(3x120)

(4x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm for metric use

S-0007-F

***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.

Notes

OM-4409 Page 29

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5-10. Connecting To Remote 14 Receptacle RC14

Socket*

Socket Information

24 volts ac. Protected by sup-

plementary protector CB5.

24 VOLTS AC

Contact closure to A completes

24 volt ac contactor control

circuit.

Output to remote control:+10

volts dc in MIG or Stick mode;

0 to +10 volts dc in TIG mode.

Remote control circuit common.

REMOTE

OUTPUT

CONTROL

DC input command signal: 0 to

+10 volts from min. to max. of

remote control with Voltage/

Amperage Adjust control at

max.

115 volts, 10 amperes, 60 Hz

ac. Protected by supplementary

protector CB6.

115 VOLTS AC

Contact closure to I completes

115 volt ac contactor control

circuit.

Chassis common.

GND

803 231

NEUTRAL

Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Notes

OM-4409 Page 30

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5-11. Connecting To The Air Compressor

Stop engine and release air pres-

sure before servicing compressor.

Open Position

Closed Position

803 231

Be sure valve is in open position when us-

ing air compressor.

The compressor runs and air pressure is

available whenever the engine is running

and the front panel Compressor switch is

moved to the On position (see Section 6-1).

Run engine at weld/power speed for maxi-

mum air compressor output. Compressor

output is reduced when engine is running at

idle speed.

The air compressor will not start if still under

pressure. If air compressor is turned off,

wait for air pressure to bleed off (about 20

seconds) before turning air compressor on

again.

Air pressure is present at air shutoff

valve whenever Air Pressure Gauge

on front panel indicates air

pressure.

3/4 in NPT Air Pressure

Fitting

Air Shutoff Valve

. Using the air compressor does not sig-

nificantly affect weld or generator pow-

er output.

Connect air hose with 3/4 in NPT fitting (not

supplied) to air shutoff valve.

OM-4409 Page 31

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SECTION 6 − OPERATING THE WELDING GENERATOR

6-1. Controls (See Section 6-2)

803 229 / 217 356-A

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6-2. Description Of Controls (See Section 6-1)

Engine Starting Controls

Starting Aid Switch

Use switch to energize starting aid for cold

weather starting.

Engine Oil Pressure Gauge

and do not represent an actual percent-

age value.

Normal pressure is 30 − 60 psi (206 − 414

kPa). Engine stops if pressure is below 20 psi 13 Panel/Remote Switch And Remote 14

(138 kPa).

Receptacle

Engine Temperature Gauge

Use switch to select front panel or remote

voltage/amperage control. For remote con-

trol, place switch in Remote position and con-

nect remote control to Remote 14 receptacle

RC14 (see Sections 5-10 and 6-4).

14 Polarity/AC Selector Switch (Optional)

Or Output Selector Switch (Optional)

Push switch up for 60 seconds to operate the

starting aid (intake air heater) before cranking

engine (see starting instructions following).

Normal temperature is 212 - 239° F (100 -

115° C). Engine stops if temperature exceeds

270° F (132° C).

Engine Control Switch

Battery Voltmeter

Use switch to start engine, select engine

speed, and stop engine.

In Run position, engine runs at weld/power

speed. In Run/Idle position, engine runs at

idle speed with no generator power or weld

load, and weld/power speed with load ap-

plied.

Use gauge to check battery voltage and moni-

tor the engine charging system. The meter

should read about 14 volts dc when the en-

NOTICE − Do not switch under load.

gine is running, and about 12 volts dc when Use Polarity/AC selector switch to select AC

the engine is stopped.

Air Compressor Hour Meter (Optional)

or DC weld output and DC weld output po-

larity.

Use Output Selector switch to select AC

Weld, DC Weld, or battery charge output (see

Section 8-1).

Weld Meters

15 AC/DC Voltmeter (Optional)

The air compressor load does not affect en-

gine speed. Run engine at weld/power speed

for maximum air compressor output.

Use gauge to monitor compressor running

time for scheduling maintenance.

Weld Controls

10 Process/Contactor Switch

See Section 6-3 for Process/Contactor

switch information.

11 Ampere Range Switch

NOTICE − Do not switch under load.

Use switch to select weld amperage range.

Use all five ranges for Stick welding, and the

lowest four ranges for TIG welding. Read the

upper set of numbers at each range for Stick

welding and the lower set at each range for

TIG welding.

To Start:

. If engine does not start, let engine come

to a complete stop before attempting re-

start.

Above 325 F (05 C): turn Engine Control

switch to Start. Release Engine Control

switch when engine starts.

Voltmeterdisplays voltage at the weld output

terminals, but not necessarily the welding arc

due to resistance of cable and connections.

16 AC/DC Ammeter (Optional)

Ammeter displays amperage output of the

unit.

Air Compressor Controls

17 Air Compressor Switch

Use switch to turn air compressor on and off.

Air pressure is present at the compressor air

shutoff valve whenever the compressor is

running. The compressor shuts off when the

enginestops. To use air, the compressor must

be turned on each time the engine is started.

The air compressor will not start if still under

pressure. If air compressor is turned off, wait

for air pressure to bleed off (about 20 sec-

onds) before turning air compressor on again.

Below 325 F (05 C) using starting aid

switch:

Turn Engine Control switch to Run/Idle posi-

tion. Push Starting Aid switch up for 60 sec-

onds. While still holding Starting Aid switch,

turn Engine Control switch to Start. Release

Engine Control switch and Starting Aid switch

when engine starts.

To Stop: turn Engine Control switch to Off

position.

Engine/CompressorGauges

Use the highest range for MIG welding and for

cutting and gouging (CAC-A).

For most welding applications, use lowest

amperagerange possible to help prevent arc

outages.

12 Voltage/AmperageAdjust Control

With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage

within range selected by Ampere Range

switch. With Process/Contactor switch in any

MIG position, use control to adjust voltage.

With Panel/Remote Switch in Remote posi-

tion, control limits the remote amperage in

TIG mode, but has no effect in Stick and MIG

modes.

Engine Hour Meter

Use gauge to monitor engine running time for

schedulingmaintenance.

. To extend clutch bearing life, cycle air

compressor off and on once every two

hours during periods of extended use.

Fuel Gauge

Use gauge to check fuel level. Engine stops

if fuel level is low on units with low fuel shut-

down option.

To check fuel level when engine is not run-

ning, turn Engine Control switch to Run/Idle

position.

18 Air Shutoff Valve

Air pressure is present at valve when-

ever Air Pressure Gauge (item 5) indi-

cates air pressure.

Weld output would be about 263 A DC with

controls set as shown (50% of 125 to 400 A).

Close valve to stop air flow when connecting

or changing tools or air hoses (see Section

Air Pressure Gauge

Use gauge to check compressor air pressure.

age Adjust control are for reference only 5-1 1).

OM-4409 Page 33

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6-3. Process/Contactor Switch

Process/Contactor Switch

Weld output terminals are ener-

gized when Process/Contactor

switch is in a Weld Terminals Al-

ways On position and the en-

gine is running.

DC voltage is still present at the

weld terminals when Process/

Contactor switch is in the Re-

mote On/Off Switch Required −

Stick position and the engine is

running.

Use switch to select weld process and

weld output on/off control (see table be-

low and Section 6-4).

Place switch in Remote On/Off Switch

Required positions to turn weld output

on and off with a device connected to

the remote 14 receptacle.

Place switch in Weld Terminals Always

On positions for weld output to be on

whenever the engine is running.

Use Stick position for air carbon arc

(CAC-A) cutting and gouging.

When switch is in a Stick position, the

arc drive (dig) circuit provides addition-

al amperage during low voltage (short

arc length conditions) to prevent “stick-

ing” electrodes.

The arc drive (dig) circuit is disabled

when switch is in MIG or TIG positions.

. The engine auto idle option does

not work in the Remote On/Off

Switch Required-TIG mode.

217 356-A

Process/Contactor Switch Settings

Switch Setting

Process

Output On/Off Control

Engine Auto Idle (Optional)

Remote On/Off Switch Re-

quired − TIG, HF Required

Or Scratch Start TIG

GTAW With HF Unit, Pulsing

Device, Or Remote Control

At Remote 14 Receptacle

Not Active

Remote On/Off Switch

Stick (SMAW) With Remote On/Off

MIG (GMAW)

At Remote 14 Receptacle

Electrode Hot

Active

Required − Stick

Remote On/Off Switch

Required − CV Feeder

Using Remote

Weld Terminals Always On −

MIG (GMAW)

Wire

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

Weld Terminals Always On −

Electrode Hot

Stick

Weld Terminals Always On −

TIG Scratch Start (GTAW)

Electrode Hot

TIG, Scratch Start

OM-4409 Page 34

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6-4. Using Remote Voltage/Amperage Control

Remote 14 Receptacle RC14

Connect optional remote control to

RC14 (see Section 5-10).

803 231

In Example:

Process = Stick (Using Remote On/Off)

Range = 125 to 400 A DC

Min = 125 A DC

Example: Combination Remote Amperage Control (Stick)

Max = 400 A DC

Max (400 A DC)

Min (125 A DC)

Set Remote

Process

Set

Set Range

Control Not Used

In Remote On/Off

Switch Required −

Stick Mode

Adjust Optional Remote Control

Panel/Remote

Switch

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 330 A DC

Example: Combination Remote Amperage Control (TIG)

Percentage Of Range = 50%

Min = 40 A DC

Max = About 185 A DC (50% of 40 to 330)

Max (185 A DC)

Min (40 A DC)

Set Remote

Process

Set

Set Control

Adjust Optional Remote Control

Set Range

Panel/Remote

Switch

0774 / Ref. 217 356-A / 803 231

OM-4409 Page 35

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SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Receptacles

120 V 20 A AC GFCI

Receptacle GFCI1

240 V 30 A AC Twistlock

Receptacle RC1

Receptacles supply 60 Hz single-

phase power at weld/power speed.

If a ground fault is detected, GFCI

Reset button pops out and

receptacle does not work. Check

for faulty tools plugged in

receptacle. Press button to reset

GFCI1.

. At least once a month, run en-

gine at weld/power speed and

press test button to verify GFCI

is working properly.

Supplementary Protector CB1

Supplementary Protector CB2

CB1 protects RC1 and the genera-

tor winding from overload. If CB1

opens, RC1 and GFCI1 do not

work. Place switch in On position to

reset.

CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not

work. Press button to reset.

. If a supplementary protector

continues to open, contact

Factory Authorized Service

Agent.

fected by weld output.

Maximum output is 2.4 kVA/kW

from GFCI1 and 4 kVA/kW from

RC1. Maximum output from all re-

ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from

RC1, only 7 A is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

191 624

OM-4409 Page 36

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7-2. Connecting To Optional AC Power Plant

power plant.

. Place Process/Contactor switch in

Weld Terminals Always On - Stick

position when using optional ac

power plant (see Section 6-3).

Single-Phase Power Connection

Single-Phase Generator Power

120/240 V 50 A Receptacle RC5

RC5 is connected to the optional ac

power plant and supplies 60 Hz single-

phase power at weld/power speed.

Maximum output from RC5 is 12 kVA/

kW. Power available at RC5 is reduced

when welding.

Supplementary Protector CB7

Supplementaryprotector CB7 protects

single-phasereceptacle RC5 and the

load wires from overload. If CB7

opens, all generator ac output stops

and the receptacle does not work.

Three-Phase Power Connection

Single

Phase

Three

Phase

Output

Three-Phase Generator Power

Volts

120/240

240

Stop engine.

Close panel opening

if no connections are

made to power plant.

Amps

KVA/KW

Power and weld outputs are live

at the same time. Disconnect or

insulate unused cables.

Frequency

Engine Speed

60 Hz

1850 RPM

. Have qualified person install ac-

cording to circuit diagram and

Generator Power Guidelines (see

Section 16).

Lead 42 connects to GROUND stud on

front of unit.

Jumper 42 is connected to 90 at factory.

Remove power panel mounting

screws. Tilt panel forward.

Lead 93

Remove plug

before inserting

leads. Reinstall

bushing.

Lead 92

Lead 91

Lead 42 (Circuit Grounding Lead)

Lead 90 (Neutral)

Isolated Neutral Terminal

Jumper Lead 42

Rear Of Panel

10 Grounding Terminal

Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon-

nected from neutral to meet applicable

electrical codes.

Lead 42 connects to front panel

Ground stud.

11 User-Supplied Leads

12 Supplementary Protector CB7

User Terminals

Connect user-supplied leads to termi-

nals on CB7 and to the isolated neutral

terminal and grounding terminal as

necessary.

panel

opening if no

connections

are made to

power plant.

. Supplementaryprotector CB7 pro-

tects single-phase receptacle RC5

and the load wires from overload.

If CB7 opens, all ac power plant

output stops and the receptacle

does not work.

240V

120V

1-Phase

3-Phase

120V

Tools Needed:

240V

Reinstall power panel.

240V

Ref. 197 399 / 802 332-B

OM-4409 Page 37

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7-3. Optional Generator Power Receptacles

120 V 20 A AC GFCI

Receptacle GFCI1

240 V 16 A AC European

Receptacle RC1

European Receptacle

240 V 15 A AC Australian

Receptacle RC1

240 V 15 A AC South African

Receptacle RC1

Receptacles supply 60 Hz single-

phase power at weld/power speed.

If a ground fault is detected, the

GFCI Reset button pops out and

the receptacle does not work.

Check for faulty tools plugged in

receptacle. Press button to reset

GFCI1.

gine at weld/power speed and

press test button to verify GFCI

is working properly.

Australian Receptacle

Supplementary Protector CB2

Supplementary Protector CB3

CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not

work. Place button to reset breaker.

CB3 protects RC1 from overload. If

CB3 opens, RC1 does not work.

Press button to reset breaker.

. If a supplementary protector

continues to open, contact

Factory Authorized Service

Agent.

fected by weld output.

South African Receptacle

Maximum output is 2.4 kVA/kW

from GFCI1 and 4 kVA/kW from

RC1. Maximum output from all re-

ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from

RC1, only 7 A is available at GFCI1:

(240 V x 13 A) + (120 V x 7 A) =

4.0 kVA/kW

191 624

OM-4409 Page 38

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SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER

8-1. Battery Charge Controls

Output Selector Switch

NOTICE − Do not switch under load. Stop en-

gine or set Process/Contactor switch to any

Remote position before switching.

Use switch to select weld or battery charge

output. Output automatically decreases (but

does not stop) when terminal voltage is 15 to

25 percent above required battery voltage.

. Before connecting charging cables, place

Output Selector switch in position match-

ing voltage of battery being charged.

When done charging, stop engine or set Pro-

cess/Contactor switch to any Remote On/Off

Switch Required position. Move Output Selec-

tor switch to AC Weld or DC Weld position.

803 231-A / 210 149-B

8-2. Determining Battery Charging Current

Battery Charging Current

Chart

Find battery cold crank amp (CCA)

rating on battery. Use CCA rating

on chart to find charge current set-

ting for battery.

400

350

300

250

200

150

EXAMPLE: If battery CCA rating is

500, charging current from chart is

100 amperes.

Do not exceed charging current

found on chart. For longer battery

life, use lowest charge rate

possible.

100

500

1000

1500

2000

BATTERY COLD CRANK AMP RATING (CCA)

142 975-B

OM-4409 Page 39

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8-3. Battery Charge Cable Connections

−

803 231-A / 210 156 / Ref. S-0714 / Ref. S-0756

Use lugs of proper amperage capacity and

hole size for connecting to charge output

terminals.

Stop engine.

Read BCI Battery Service Manual

before charging or jump starting.

Do not charge or jump start a battery

which has loose terminals or one

showing damage such as a cracked

case or cover.

Install suitable connectors on remaining

ends of battery cables.

. Before connecting to battery, place

Output Selector switch in position

matching voltage of battery being

charged.

Battery Charge Positive (+) Output

Terminal

Have only qualified persons do bat-

tery charging work.

Battery Charge Negative (−) Output

Terminal

Battery

Battery Charging Cables

Keep cables away from moving

parts.

. Connect charging cables to battery

charge output terminals before con-

necting to battery terminals.

For battery charging, use less than 20 feet

(6.1 m) of AWG #1 or larger cable. For jump

starting, use less than 20 feet (6.1 m) of

AWG 2/0 or larger cable.

Do not use damaged cables.

Connect Battery Charge Positive (+) cable

to battery positive (+) terminal, and battery

Charge Negative (−) cable to battery nega-

tive (−) terminal.

Be sure charger output voltage

matches battery voltage.

Terminal Lug

OM-4409 Page 40

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8-4. Battery Charging Procedure

In Example:

Battery Voltage = 12 Volts

Battery CCA Rating = 500

Charge Current = 100 A (See Section 8-2)

Ampere Range Setting = 55 to 125 A

V/A Control Setting = Any Position

. This battery charging procedure uses

the front panel controls to turn charging

output on and off.

Set Output Selector Switch To

Voltage Of Battery Being

Charged (12 Or 24 Volt).

Stop Engine.

Set Process/Contactor Switch To

Any Remote On/Off Switch Required

Position.

NOTICE− Do not switch under load.

−

Connect Cables (Observe

Correct Polarity).

Determine Charge Current From

Battery CCA Rating And Chart

(See Section 8-2).

Set Ampere Range Switch To Lowest

Range That Exceeds Charge Current.

NOTICE− Do not switch under load.

Start Engine.

Set Process/Contactor Switch

To Any Weld Terminals Always On

Position To Begin Charging.

Charge 10 minutes. Check

Battery Voltage. Continue

Charging If Necessary.

. To control battery charging output using a

remote device connected to the Remote

14 receptacle, keep Process/Contactor

switch in Remote On/Off Switch Required

position and use remote device to turn

charging output on and off.

OM-4409 Page 41

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8-5. Jump Starting Procedure

jump starting battery.

Stop Engine.

Set Output Selector Switch To

Voltage Of Battery Being

Charged (12 Or 24 Volt).

Set Process/Contactor Switch To

Any Remote On/Off Switch Required

Position.

NOTICE− Do not switch under load.

−

Set Ampere Range Switch To

300-Max Position.

Connect Cables (Observe

Correct Polarity).

NOTICE− Do not switch under load.

Connect Remote

Control Device

(Momentary-On

Switch).

Press (close)

switch only while

cranking engine of

equipment being

started.

Start Engine.

Press (Close) Remote Momentary-On

Switch While Cranking Engine Of Equip-

ment Being Jump Started. Release Switch

When Equipment Starts. Stop Welding

Generator And Disconnect Cables.

Stop Engine.

Disconnect

Cables.

OM-4409 Page 42

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SECTION 9 − ENGINE/GENERATOR MAINTENANCE

9-1. Engine Maintenance Label

OM-4409 Page 43

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9-2. Routine Engine/Generator Maintenance

Stop engine before maintaining.

. See Engine Manual and Maintenance Label

for important start-up, service, and storage

information. Service engine more often if

used in severe conditions.

Recycle engine

fluids.

Reference

* To be done by Factory Authorized Service Agent

Every

Hours

Section 5-7,

9-6

FUEL

WATER

Every

Hours

Every

100

Hours

Section 9-4

Every

250

Hours

Engine

Manual,

Section 9-5

1/2 in.

(13 mm)

Every

500

Hours

Every

1000

Hours

Section 9-6,

9-3 and

FUEL

Engine

Manual

SLUDGE

~ Slip Rings*

Brushes*

Every

3000

Hours

Every

6000

Hours

or 5

Years

OM-4409 Page 44

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9-3. Checking Generator Brushes

Stop engine and let cool.

Generator Brush

Remove brushes from brush holder.

Replace brushes if damaged or if brush

materialis at or near minimum length.

Minimum Length:

5/8 in (16 mm)

New Length: 1-1/4 in (32 mm)

Replace

Damaged Brushes

Ref. 206 467

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

16 Gauge (.063 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4409 Page 45

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9-4. Servicing Engine Air Cleaner

Stop engine.

NOTICE − Do not run engine without air

cleaner or with dirty element. Engine

damagecaused by using a damaged ele-

ment is not covered by the warranty.

Engine Air Cleaner

be cleaned but the dirt holding capac-

ity of the filter is reduced with each

cleaning. The chance of dirt reaching

the clean side of the filter while clean-

ing and the possibility of filter damage

makes cleaning a risk. Consider the

risk of unwarrantable equipment

damage when determining whether

to clean or replace the primary ele-

ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-

ling an optional safety element to pro-

vide additional engine protection.

Never clean a safety element. Re-

place the safety element after servic-

ing the primary element three times.

Clean or replace primary element if dirty

(see note above before cleaning). Re-

place primary element if damaged. Re-

place primary element yearly or after six

cleanings.

Housing

Safety Element (Optional)

Primary Element

Dust Cap

Dust Ejector

Optional

To clean air filter:

Wipe off cap and housing. Remove cap

and dump out dust. Remove element(s).

Wipe dust from inside cap and housing

with damp cloth. Reinstall safety element

(if present). Reinstall cap.

NOTICE − Do not clean housing with air

hose.

Clean primary element with compressed

air only.

Air pressure must not exceed 100 psi

(690 kPa). Use 1/8 in (3 mm) nozzle and

keep nozzle at least 2 in (51 mm) from

inside of element. Replace primary ele-

ment if it has holes or damaged gaskets.

Keep nozzle

2 in (51 mm)

from element.

Reinstall primary element and cap (dust

ejector down).

Blow

Inspect

aircleaner1 9/00 − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B

OM-4409 Page 46

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9-5. Inspecting/Cleaning Optional Spark Arrestor Muffler

Stop engine and let cool.

Spark Arrestor Muffler

Cleanout Plug

Remove plug and remove any dirt

covering cleanout hole.

Start engine and run at idle speed to

blow out cleanout hole. If nothing

blows out of hole, briefly cover end

of exhaust pipe with fireproof

material.

Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

803 228 / 803 230

OM-4409 Page 47

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9-6. Adjusting Engine Speed

Stop engine and let cool.

Engine speed is factory set and

should not require adjustment. Af-

ter tuning engine, check engine no

load speed with a tachometer or fre-

quency meter (see table for no load

speeds). If necessary, adjust speed

as follows:

Start engine and run until warm.

Turn Process/Contactor switch to

Weld Terminals Always On − Stick

position.

Throttle Rod

Locknut

Loosen locknuts. Place engine

control switch in Run/Idle position.

Wait 15 seconds for throttle sole-

noid to energize and lower engine

speed to idle rpm.

Turn throttle rod to adjust idle

speed. Tighten locknuts.

Engine Speed Adjustment

Screw

Locknut

Place engine control switch in Run

position.

Loosen locknut. Turn screw to ad-

just weld/power speed. Tighten

locknut.

than specified.

Stop engine.

Close door.

1850 rpm Max.

(61.6 Hz)

1235 rpm

(41.1 Hz)

Tools Needed:

3/8, 7/16 in

803 228 / 802 313-A

OM-4409 Page 48

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9-7. Servicing Engine Fuel And Lubrication Systems

Tools Needed:

Right Side

803 228

base. Be sure to select the correct hose

when draining engine oil.

To replace secondary fuel filter:

See engine manual.

Close doors.

Stop engine and let cool.

After servicing, start engine and

check for fuel leaks. Stop engine,

tighten connections as necessary,

and wipe up spilled fuel.

Oil Filter

Oil Drain Hose And Valve

Oil Fill Cap

Route engine oil drain hose through hole in

base. See engine manual and engine main-

tenance label for oil specifications.

To drain sludge from fuel tank:

Beware of fire. Do not smoke and

keep sparks and flames away from

drained fuel. Dispose of drained fuel

in an environmentally-safe manner.

Do not leave unit unattended while

draining fuel tank.

To drain water from fuel system:

Open primary fuel filter petcock and drain

water into metal container. Close petcock

when water-free fuel flows.

Primary Fuel Filter (Fuel/Water

Separator)

To replace primary fuel filter:

Properly lift unit and secure in a level

position. Use adequate blocks or

stands to support unit while drain-

ing fuel tank.

Turn filter counterclockwise. Remove filter.

Petcock

Secondary Fuel Filter

Fuel Tank Sludge Drain Valve

Apply thin coat of fuel to gasket on new filter.

Fill filter with fuel. Install filter and turn clock-

wise until tight. Bleed air from fuel system

according to engine manual.

Attach 1/2 ID hose to drain valve. Put metal

container under drain, and use screwdriver

to open sludge drain valve. Close valve

when sludge has drained. Remove hose.

To change oil and filter:

Inspect fuel lines, and replace if cracked or

worn.

drain hoses are located together in the

OM-4409 Page 49

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9-8. Engine/Generator Overload Protection

Stop engine.

circuit breaker or fuse opens, it

usually indicates a more serious

problem exists. Contact Factory

Authorized Service Agent.

sor overload protection.

Fuse F1

Fuse F2

F1 and F2 protect the stator exciter

winding from overload. If F1 opens,

weld and generator power is low or

stops entirely. If F2 opens, weld output

is low or stops entirely. 4 kVA/kW gen-

erator power is still available.

Circuit Breaker CB4 (Not Shown)

Supplementary Protector CB5

Supplementary Protector CB6

Circuit Breaker CB10 (Not

Shown)

Supplementary Protector CB11

Supplementary Protector CB12

Supplementary Protector CB13

10 Circuit Breaker CB14

(Not Shown)

CB4 protects the welding arc drive (dig)

circuit. If CB4 opens, electrode may

stick to the workpiece more frequently

during low voltage (short arc length)

conditions. CB4 automatically resets

when the fault is corrected.

CB5 protects the 24 volt ac output to re-

mote receptacle RC14, and 24 volt out-

put to field current regulator board PC1.

If CB5 opens, weld output and 24 volt

output to RC14 stops. On units with op-

tional power plant, power at receptacle

RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to

remote receptacle RC14. If CB6 opens,

115 volt output to RC14 stops.

CB10 protects the engine battery cir-

cuit. If CB10 opens, the engine will not

crank. CB10 automatically resets when

the fault is corrected.

CB11 protects the engine wiring har-

ness. If CB11 opens, weld output stops

(generatorpower is still available).

CB12 protects the field flashing circuit.

If CB12 opens, the generator may not

excite at start-up and weld and genera-

tor power output may not be available.

CB13 protects the engine shutdown cir-

cuit. If CB13 opens, the engine cranks

but does not start.

Press button to reset.

CB14 protects the throttle solenoid. If

CB14 opens, the engine will not run at

idle speed. CB14 automatically resets

when the fault is corrected.

803 229

OM-4409 Page 50

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SECTION 10 − AIR COMPRESSOR MAINTENANCE

reduced to 2 years if non-Ingersoll Rand oil and filters are used

The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment. The compres-

sor will require service more often if used in dirty, humid conditions.

10-1. Air Compressor Maintenance Label

OM-4409 Page 51

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10-2. Routine Air Compressor Maintenance

Stop engine before maintaining.

. See Compressor Maintenance Label for im-

portant start-up, service, and storage infor-

mation. Service air compressor more often

if used in severe conditions.

Recycle air

compressor

fluids.

Reference

Section 5-7

* To be done by Factory Authorized Service Agent

Every

Hours

Every

100

Hours

Every

250

Hours

Section

10-3

l Worn or Damaged Air/Oil

Hoses

Every

500

Hours

Section

10-5

Every

1000

Hours

Section

10-5

OM-4409 Page 52

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10-3. Servicing Compressor Air Cleaner

Stop engine.

NOTICE − Do not run air compressor

without air cleaner or with dirty element.

Compressor damage caused by using a

damaged element is not covered by the

warranty.

Compressor Air Cleaner

. Remove engine air cleaner cover

and element to access compressor

air cleaner (see Section 9-4)

. The air cleaner primary element can

be cleaned but the dirt holding capac-

ity of the filter is reduced with each

cleaning. The chance of dirt reaching

the clean side of the filter while clean-

ing and the possibility of filter damage

makes cleaning a risk. Consider the

risk of unwarrantable equipment

damage when determining whether

to clean or replace the primary ele-

ment.

If you decide to clean the primary ele-

ment, we strongly recommend instal-

ling an optional safety element to pro-

vide additional air compressor

protection.Never clean a safety ele-

ment. Replace the safety element af-

ter servicing the primary element

three times.

Clean or replace primary element if dirty

(see note above before cleaning). Re-

place primary element if damaged. Re-

place primary element yearly or after six

cleanings.

Housing

Safety Element

Primary Element

Cover

Dust Ejector

To clean air filter:

Wipe off cover and housing. Remove

cover and dump out dust. Remove ele-

ment(s). Wipe dust from inside cover and

housing with damp cloth. Reinstall safety

element (if present). Reinstall cover.

NOTICE − Do not clean housing with air

hose.

Keep nozzle

2 in (51 mm)

from element.

Clean primary element with compressed

air only.

Air pressure must not exceed 100 psi

(690 kPa). Use 1/8 in (3 mm) nozzle and

keep nozzle at least 2 in (51 mm) from

inside of element. Replace primary ele-

ment if it has holes or damaged gaskets.

Reinstall primary element and cover

(dust ejector down).

Blow

Inspect

aircleaner1 9/02* − 803 228 / 153 929-B / 153 585 / Ref. S-0698-B

OM-4409 Page 53

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10-4. Compressor Overload Protection

Stop engine.

. When a circuit breaker or fuse

opens, it usually indicates a more

serious problem exists. Contact

Factory Authorized Service Agent.

tor overload protection.

Circuit Breaker CB15

Circuit breaker CB15 protects the air

compressor clutch. If CB15 opens, the

compressor does not run and air output

stops.

Press button to reset breaker.

803 228 / 803 229

OM-4409 Page 54

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10-5. Servicing Air Compressor

Tools Needed:

7/8, 15/16 in

Too

High

Full

Right Side

Too

Low

803 228

To change compressor oil and filter:

Add recommended oil until oil level indicator

shows system is full (see compressor mainte-

nance label for oil specifications). Reinstall oil

fill cap. Tighten cap with wrench.

Stop engine and let cool. Wait 20 sec-

onds for system pressure to drop be-

fore changing oil.

. The engine oil drain and compressor oil

drain hoses are located together in the

base. Be sure to select the correct hose

when draining compressor oil.

Air Compressor Oil Filter

To replace air/oil separator:

Air Compressor Air/Oil Separator

Loosen nut securing tube on separator base.

Lift oil scavenge tube from separator. Turn fil-

ter counterclockwise. Remove filter.

tings are in place before reinstalling caps.

Drain compressor oil while compressor is still

warm.

Air Compressor Oil Drain Hose

w/Removable Cap

Route compressor oil drain hose through hole

in base. Remove compressor oil fill cap. Re-

move cap from oil drain hose and drain oil into

a suitable container. Reinstall oil drain hose

cap. Tighten cap with wrench.

Apply thin coat of oil to gasket on new filter.

Install filter and turn clockwise. Reinstall oil

scavenge tube.

Air Compressor Oil Fill Cap

Start engine, run air compressor, and check

for oil leaks.

Air Compressor Oil Level Indicator (On

Tank)

Remove filter by turning filter counterclock-

wise. Remove filter. Apply thin coat of oil to

gasket on new filter. Install new filter and turn

clockwise until tight.

Stop engine.

Oil Scavenge Tube

OM-4409 Page 55

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10-6. Adjusting Compressor Air Pressure

Check compressor air pressure using

air pressure gauge known to be accu-

rate. If necessary, adjust air pressure

as follows:

Screw

Tools Needed:

5/16, 3/8 in

Loosen jam nut securing screw. Turn

screw clockwise (increase pressure)

or counterclockwise (decrease) until

pressure is 125 psi (862 kPa).

if compressor air pressure is set

above 125 psi (862 kPa).

Tighten nut.

Pressure Relief Valve

Pressure relief valve opens and re-

leases pressure at 150 psi (1034

kPa). The pressure relief valve is not

adjustable.

803 228

OM-4409 Page 56

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SECTION 11 − TROUBLESHOOTING

11-1. Troubleshooting Tables

A. Welding

Trouble

Remedy

No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote

okay at ac receptacles.

On/Off Switch Required position and connect remote contactor to Remote 14 receptacle RC14 (see Sec-

tions 5-10 and 6-1).

Check position of Ampere Range switch.

Check position of optional Output Selector switch (see Section 8-1).

Reset supplementary protector CB11 (see Section 9-8).

Reset supplementary protector CB5 (see Section 9-8). Check for faulty remote device connected to

RC14.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Have Factory Authorized Service Agent check connector board PC6 and connections.

Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check

brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

No weld output or generator power Disconnect equipment from generator power receptacles during start-up.

output.

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Reset supplementary protector CB12 (see Section 9-8).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

Check and tighten connections inside and outside unit.

Erratic weld output.

High weld output.

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

Check position of Ampere Range switch and Voltage/Amperage Adjust control.

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

Have Factory Authorized Service Agent check field current regulator board PC1.

Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere

work when welding in Stick mode.

Range switch in highest range.

Low weld output.

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).

frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

length) conditions.

Have Factory Authorized Service Agent check optional battery charging relay CR7.

Low open-circuit voltage.

Check engine weld/power speed, and adjust if necessary.

No remote fine amperage or voltage Place Panel/Remote Switch in Remote position.

control.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Repair or replace remote control device.

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Trouble

Remedy

Constant speed wire feeder does not Reset supplementary protector(s) CB5 and CB13 (see Section 9-8).

work.

Check and secure connections to Remote 14 receptacle RC14 (see Section 5-10).

Repair or replace wire feeder.

Low CV weld output.

Set Ampere Range switch to highest range.

Min or max CV weld output only.

Check position of Voltage/Amperage Adjust control and Panel/Remote Switch.

Repair or replace remote control device.

Have Factory Authorized Service Agent check field current regulator board PC1.

B. Standard Generator Power

Trouble

Remedy

No generator power output at ac recep- Reset receptacle supplementary protectors.

tacles; weld output okay.

No generator power or weld output.

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check field current regula-

tor board PC1 (see Section 10-4).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

High output at generator power Check engine weld/power speed, and adjust if necessary (see Section 9-6).

receptacles.

Have Factory Authorized Service Agent adjust field current resistor R3.

Low output at generator power Check engine weld/power speed, and adjust if necessary (see Section 9-6).

receptacles.

Check fuse F1, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte-

grated rectifier SR1, resistor R3, and capacitor C9.

C. Optional AC Power Plant

Trouble

Remedy

No or low output at optional ac power

plant/receptacle RC5.

Place Process/Contactor switch in Weld Terminals Always On - Stick position (see Section 6-3).

Reset supplementary protector CB7 (see Section 7-2).

Reset supplementary protector CB5 (see Section 9-8).

Check engine weld/power speed, and adjust if necessary (see Section 9-6).

Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

PC1.

High output at optional ac power plant/ Check engine weld/power speed, and adjust if necessary (see Section 9-6).

receptacle RC5.

Have Factory Authorized Service Agent check field current regulator board PC1.

Erratic output at optional ac power plant/ Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board

receptacle RC5.

PC1.

OM-4409 Page 58

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D. Engine

Trouble

Remedy

Engine will not crank.

Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8).

Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

Turn optional battery disconnect switch to On position (see Section 5-6).

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, and diode/

capacitor board D8/C8.

Engine cranks but does not start.

Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.

Reset supplementary protector CB13 (see Section 10-4 ). Have Factory Authorized Service Agent check

engine wiring harness and components.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,

and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Engine Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature

Control switch is released.

is too high (see Section 5-7).

Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.

Engine hard to start in cold weather.

Use starting aid switch (see Section 6-1). If Starting Aid switch does not work have Factory Authorized

Service Agent check Engine Control switch S2, and control relay CR8.

Keep battery in good condition. Store battery in warm area off cold surface.

Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for

fuel information.

Use correct grade oil for cold weather (see Section 9-1 ).

Engine suddenly stops.

Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature

is too high (see Section 5-7).

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,

and fuel solenoid FS1.

See engine manual.

Check fuel level.

Engine slowly stopped and cannot be

restarted.

Check engine air and fuel filters (see Sections 9-4 and 9-7).

See engine manual.

Battery discharges between uses.

Turn Engine Control switch S1 off when unit is not running.

Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Have Factory Authorized Service Agent check idle module PC7.

Engine idles, but does not come up to

weld speed.

Check for obstructed throttle solenoid.

OM-4409 Page 59

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Trouble

Remedy

Turn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG.

Check for obstructed throttle solenoid.

Engine does not run at idle speed.

Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1

and linkage (see Section 9-8).

Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current

transformer CT1.

Engine uses oil during run-in period; Dry engine (see Section 14).

wetstacking occurs.

E. Air Compressor

Trouble

Remedy

Air compressor does not operate; no air Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If

pressure at air shutoff valve.

compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor

on again.

Reset supplementary protector CB15 (see Section 10-4).

Check compressor belt tension. Be sure correct belt is used and is properly installed.

Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pres-

sure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.

Air compressor stops after short period Check compressor oil level (see Section 5-7). Automatic shutdown stops compressor if compressor tem-

of operation.

perature is too high.

Clean debris from radiator. Automatic shutdown stops compressor if compressor temperature is too high.

Check for leaks in air lines and hoses.

Low air pressure.

Adjust compressor air pressure (see Section 10-6).

Check air compressor air cleaner (see Section 10-3).

Have Factory Authorized Service Agent check compressor for rated output.

Adjust compressor air pressure (see Section 10-6).

High air pressure.

Be sure control line is connected at regulator valve and inlet valve.

Pneumatic tools freeze up because of Install optional air dryer/filter kit (Part No. 195 117).

moisture in compressed air.

Oil in air from compressor.

Check compressor oil level (see Section 5-7). If oil level is too high, system becomes saturated with oil.

Change compressor air/oil separator (see Section 10-5).

Check connections of control lines (see air compressor circuit diagram in Section 12).

Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.

Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.

Oil in compressor air cleaner.

F. Optional Battery Charging

Trouble

Remedy

No battery charge output; weld output

okay.

Place Output Selector switch in 12 Volt Charge or 24 Volt Charge position.

Check and tighten battery connections if necessary.

Turn on remote control device or turn Process/Contactor switch to any Weld Terminals Always On

position (see Section 6-3).

No battery charge or weld output.

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent

check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Reset supplementary protector CB12 (see Section 9-8).

Have Factory Authorized Service Agent check brushes and slip rings, field current regulator board PC1,

and field excitation circuit.

OM-4409 Page 60

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SECTION 12 − AIR COMPRESSOR DIAGRAM

209 059-A

Figure 12-1. Circuit Diagram For Air Compressor

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SECTION 13 − CIRCUIT DIAGRAM

Figure 13-1. Circuit Diagram For Welding Generator

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221 915−C

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SECTION 14 − RUN-IN PROCEDURE

run_in1 2007−04

14-1. Wetstacking

NOTICE − Do not perform run-in

procedure at less than 20 volts

weld output and do not exceed duty

cycle or equipment damage may

occur.

Welding Generator

Run diesel engines near rated volt-

age and current during run-in period

to properly seat piston rings and

prevent wetstacking. See name-

plate, rating label, or specifications

section in this manual to find rated

voltage and current.

NOTICE− Do not idle engine longer

than necessary. Piston rings seat

faster if engine runs at weld/power

rpm, and the welding generator is

kept loaded during run-in.

Engine Exhaust Pipe

Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs

during run-in if the engine is run too

long at light load or idle rpm.

If exhaust pipe is coated with a wet,

black, tar-like substance, dry the

engine using one of the following

run-in procedures.

See the engine manual for addition-

al engine run-in information.

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14-2. Run-In Procedure Using Load Bank

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in

procedureat less than 20 volts weld

output and do not exceed duty

cycle or equipment damage may

occur.

Load Bank

Turn all load bank switches Off. If

needed, connect load bank to 115

volts ac wall receptacle or genera-

tor auxiliary power receptacle.

Welding Generator

Place A/V range switch in maxi-

mum position, A/V control in mini-

mum position, and Output Selector

switch (if present) in either DC

position.

Weld Cables

Connect load bank to generator

weld output terminals using proper

size weld cables with correct

connectors. Observe

polarity.

correct

Start engine and run for several

minutes.

Set load bank switches and then

adjust generator A/V control so

load equals rated voltage and

current of generator (see name-

plate, rating label, or the specifi-

cations section in this manual).

Check generator and load bank

meters after first five minutes then

every fifteen minutes to be sure

generatoris loaded properly.

NOTICE − Check oil level frequent-

ly during run-in; add oil if needed.

It is recommended to run the weld-

ing generator for two hours mini-

mum and up to four hours under

load. Place A/V control in minimum

position, then turn off load bank to

remove load. Run engine several

minutes at no load.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0683

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14-3. Run-In Procedure Using Resistance Grid

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in

procedureat less than 20 volts weld

output and do not exceed duty

cycle or equipment damage may

occur.

Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

Welding Generator

Place A/V range switch in maxi-

mum position, A/V control in mini-

mum position, and Output Selector

switch (if present) in either DC

position.

Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

Voltmeter

Clamp-On Ammeter

Connect voltmeter and ammeter as

shown, if not provided on generator.

Start engine and run for several

minutes.

Set grid switches and then ad-

just generator A/V control so

load equals rated voltage and

current of the generator (see

nameplate, rating label, or the

specifications section in this

manual).

Check generator and meters after

first five minutes then every fifteen

minutes to be sure generator is

loaded properly.

NOTICE − Check oil level frequent-

ly during run-in; add oil if needed.

It is recommended to run the weld-

ing generator for two hours mini-

mum and up to four hours under

load. Place A/V control in minimum

position, then shut down grid to

remove load. Run engine several

minutes at no load.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0684

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SECTION 15 − AIR COMPRESSOR TABLES

15-1. Flow Of Free Air (CFM) Through Orifices Of Various Diameters

Orifice Diameter (in) And Free Air Flow (CFM)

Gauge Pressure (psi)

1/64

0.027

0.038

0.046

0.059

0.084

1/32

0.107

0.153

0.188

0.242

0.342

3/64

0.242

0.342

0.471

0.545

0.77

1/16

0.430

0.607

0.750

0.965

1.36

3/32

0.97

1.36

1.68

2.18

3.08

1/8

3/16

3.86

5.42

6.71

8.71

12.3

1/4

1.72

2.43

2.98

3.86

5.45

6.85

9.74

11.9

15.4

21.8

0.103

0.119

0.133

0.156

0.173

0.418

0.485

0.54

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

15.0

17.1

19.4

22.5

25.0

26.7

30.8

34.5

40.0

44.7

8.6

0.632

0.71

10.0

11.2

6.2

0.19

0.208

0.225

0.26

0.77

0.843

9.14

1.05

1.19

1.71

1.9

3.07

3.36

3.64

4.2

6.8

7.6

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

2.05

2.35

2.68

8.2

9.4

0.295

4.76

10.7

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

100

110

120

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

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

5.94

6.90

OM-4409 Page 67

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15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At

70-90 P.S.I.G.

Percent Use Factor And

MISCELLANEOUS

PORTABLE

TOOLS

MISCELLANEOUS

PORTABLE

TOOLS

Compressed Air Consumption (CF)

9 sec

3.75

5.25

15 sec

6.25

21 sec

8.75

1 min

9 sec

3.6

15 sec

6.0

21 sec

8.4

1 min

Drill, 1/18” to 3/8”

Drill, 3/8” to 5/16”

Burring Tool, Large

Rammers, Small

8.75

12.25

3.9

3.25

9.1

Screwdriver,

#2 to #6 Screw

1.8

3.0

4.2

Rammers, Medium

5.1

8.5

11.9

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

Rammers, Large

Backfill Tamper

6.0

10.0

6.25

14.0

8.75

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

12.5

18.75

5.00

8.75

Impact Wrench, 1/4”

2.25

3.75

5.3

Air Motor,

2 Horsepower

17.5

26.3

7.00

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

Air Motor,

3 Horsepower

11.25

3.0

10.5

Paint Spray Gun

(Production)

5.25

6.75

8.25

8.75

11.25

13.75

12.25

15.75

19.2

,HAMMERS

Impact Wrench, 1-1/4”

Scaling Hammer

Chipping Hammer

1.3

4.5

3.0

7.5

4.2

Die Grinder, Small

Die Grinder, Medium

2.25

3.6

3.75

6.0

5.3

8.4

10.5

Riveting Hammer,

Light

Horizontal Grinder, 2”

Horizontal Grinder, 4”

Horizontal Grinder, 6”

3.0

9.0

5.0

7.0

2.25

4.5

3.75

7.5

5.25

10.5

15.0

21.0

Riveting Hammer,

Heavy

SAWS

Circular, 8”

6.75

9.75

4.20

13.1

11.25

16.25

7.0

15.75

23.8

9.8

Horizontal Grinder, 8”

12.0

20.0

28.0

Circular, 12”

Vertical Grinders and

Sanders, 5” Pad

Vertical Grinders and

Sanders, 7” Pad

5.25

9.0

8.75

15.0

12.25

21.0

Chain, Lightweight

Chain, Heavy Duty

21.8

30.5

Vertical Grinders and

Sanders, 9” Pad

10.5

2.25

17.5

3.75

24.5

5.3

Burring Toll, Small

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.)

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SECTION 16 − GENERATOR POWER GUIDELINES

. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.

16-1. Selecting Equipment

Generator Power Receptacles

− Neutral Bonded To Frame

3-Prong Plug From Case

Grounded Equipment

2-Prong Plug From Double

Insulated Equipment

. Be sure equipment has double

insulated symbol and/or word-

ing on it.

Do not use 2-prong plug un-

less equipment is double in-

sulated.

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

16-2. Grounding Generator To Truck Or Trailer Frame

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

EquipmentGrounding

Terminal (On Front Panel)

Grounding Cable (Not

Supplied)

Metal Vehicle Frame

GND/PE

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

. Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4409 Page 69

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16-3. Grounding When Supplying Building Systems

EquipmentGrounding

Terminal

Grounding Cable

GND/PE

Use #10 AWG or larger insulated

copper wire.

Ground Device

electrical codes.

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

ST-800 576-B

16-4. How Much Power Does Equipment Require?

Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

Non-Resistive Load

VOLTS 115

Equipment with a motor is a non-re-

sistive load and requires approxi-

mately six times more power while

starting the motor than when running

(see Section 16-8).

AMPS 4.5

Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run-

ning power requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520

watts.

Example 2: If three 200 watt flood

lamps are used with the drill from Ex-

ample 1, add the individual loads to

calculate total load.

(3 x 200W) + 520 W = 1120 W

The total load applied by the three

flood lamps and drill is 1120 watts.

S-0623

OM-4409 Page 70

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16-5. Approximate Power Requirements For Industrial Motors

Industrial Motors

Rating

Starting Watts

Running Watts

Split Phase

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

800

1225

1600

2100

3175

2020

3075

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

1000

1400

1850

2400

3500

300

500

600

700

875

Capacitor Start-Induction Run

720

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

400

1-1/2 HP

2 HP

3 HP

5 HP

Capacitor Start-Capacitor Run

Fan Duty

1-1/2 HP

5 HP

7-1/2 HP

10 HP

1/8 HP

1/6 HP

1/4 HP

1/3 HP

1/2 HP

550

650

800

1100

16-6. Approximate Power Requirements For Farm/Home Equipment

Farm/HomeEquipment

Stock Tank De-Icer

Rating

Starting Watts

Running Watts

1000

1650

3400

4400

2900

10500

1720

2575

4500

6100

8200

10550

15900

23300

8100

23300

35000

46700

3300

3150

4500

6100

3100

2150

3100

2100

3200

1000

650

Grain Cleaner

1/4 HP

1/2 HP

3/4 HP

Portable Conveyor

Grain Elevator

1000

1400

1100

2800

720

Milk Cooler

Milker (Vacuum Pump)

FARM DUTY MOTORS

Std. (e.g. Conveyors,

Feed Augers, Air

Compressors)

2 HP

1/3 HP

1/2 HP

3/4 HP

1 HP

975

1400

1600

2200

2850

3900

6800

2000

6000

8000

10700

1000

950

1-1/2 HP

2 HP

3 HP

5 HP

High Torque (e.g. Barn

1-1/2 HP

5 HP

Cleaners, Silo Unloaders,

Silo Hoists, Bunk Feeders)

7-1/2 HP

10 HP

1/2 HP

500 PSI

550 PSI

700 PSI

3-1/2 cu. ft. Mixer

High Pressure 1.8 Gal/Min

Washer 2 gal/min

2 gal/min

1400

1600

800

Refrigerator or Freezer

Shallow Well Pump

1/3 HP

1/2 HP

1/3 HP

1/2 HP

750

1000

800

Sump Pump

1050

OM-4409 Page 71

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16-7. Approximate Power Requirements For Contractor Equipment

Contractor

Rating

Starting Watts

Running Watts

Hand Drill

1/4 in

3/8 in

350

400

350

400

1/2 in

600

Circular Saw

Table Saw

6-1/2 in

7-1/4 in

8-1/4 in

9 in

500

900

1400

4500

6300

2500

1720

3900

5200

3000

6000

8200

10500

1100

350

1400

1500

1800

1100

720

10 in

Band Saw

14 in

Bench Grinder

6 in

8 in

1400

1600

1000

1500

2200

2800

1100

350

10 in

Air Compressor

1/2 HP

1 HP

1-1/2 HP

2 HP

Electric Chain Saw

Electric Trimmer

Electric Cultivator

1-1/2 HP, 12 in

2 HP, 14 in

Standard 9 in

Heavy Duty 12 in

1/3 HP

500

2100

400

700

Elec. Hedge Trimmer

Flood Lights

18 in

400

HID

125

100

Metal Halide

Mercury

Sodium

Vapor

313

250

1000

1400

1250

600

1000

200

Submersible Pump

Centrifugal Pump

Floor Polisher

400 gph

900 gph

3/4 HP, 16 in

1 HP, 20 in

1/2 HP

900

500

4500

6100

3150

4500

6100

1900

900

1400

1600

950

High Pressure Washer

3/4 HP

1400

1600

700

1 HP

55 gal Drum Mixer

Wet & Dry Vac

1/4 HP

1.7 HP

900

2-1/2 HP

1300

OM-4409 Page 72

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16-8. Power Required To Start Motor

Single-PhaseInduction Motor Starting Requirements

Motor Start

Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

Motor Start Code

Running Amperage

Motor HP

AC MOTOR

Motor Voltage

VOLTS 230

AMPS 2.5

To find starting amperage:

CODE

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiplyrunning amperage by six to

find starting amperage.

1/4

PHASE 1

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper-

age required for a 230 V, 1/4 HP mo-

tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2

(11.2 x 1/4 x 1000) / 230 = 12.2A

Starting the motor requires 12.2

amperes.

S-0624

16-9. How Much Power Can Generator Supply?

Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to small-

est, and add resistive loads last.

5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

Ref. ST-800 396-A / S-0625

OM-4409 Page 73

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16-10. Typical Connections To Supply Standby Power

Have only qualified persons

perform these connections

according to all applicable

codes and safety practices.

Fused

Disconnect

Switch

Properly install and ground

this equipment according to

its Owner’s Manual and na-

tional, state, and local codes.

Welding

Generator

Output

Utility

Electrical

Service

Transfer Switch

(If Required)

. Customer-supplied equipment

is required if generator will sup-

ply standby power during

emergencies or power out-

ages.

1 Utility Electrical Service

Essential

Loads

2 Transfer Switch (Double-Throw)

Switch transfers the electrical load

from electric utility service to the

generator. Transfer load back to

electric utility when service is re-

stored.

Install correct switch (customer-

supplied). Switch rating must be

same as or greater than the branch

overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-

supplied) if required by electrical

code.

4 Welding Generator Output

Generator output voltage and wir-

ing must be consistent with regular

(utility) system voltage and wiring.

Connect generator with temporary

or permanent wiring suitable for the

installation.

Turn off or unplug all equipment

connected to generator before

starting or stopping engine. When

starting or stopping, the engine has

low speed which causes low volt-

age and frequency.

5 Essential Loads

Generator output may not meet the

electrical requirements of the prem-

ises. If generator does not produce

enough output to meet all require-

ments, connect only essential

loads (pumps, freezers, heaters,

etc. − See Section 16-4).

OM-4409 Page 74

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16-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

Load (Watts)

600

350 (106)

250 (76)

175 (53)

112 (34)

87 (26)

62 (19)

50 (15)

37 (11)

225 (68)

150 (46)

112 (34)

75 (23)

50 (15)

37 (11)

137 (42)

100 (30)

62 (19)

37 (11)

30 (9)

100 (30)

62 (19)

50 (15)

30 (9)

840

400 (122)

275 (84)

175 (53)

137 (42)

112 (34)

87 (26)

1200

1800

2400

3000

3600

4200

4800

5400

6000

400 (122)

300 (91)

225 (68)

175 (53)

150 (46)

125 (38)

112 (34)

100 (30)

87 (26)

75 (23)

62 (19)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

If unit does not have GFCI receptacles, use GFCI-protected extension cord.

Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*

Current

(Amperes)

Load (Watts)

1200

1680

2400

3600

4800

6000

7000

8400

9600

10,800

12,000

700 (213)

500 (152)

350 (107)

225 (69)

175 (53)

125 (38)

100 (31)

75 (23)

450 (137)

300 (91)

225 (69)

150 (46)

100 (31)

75 (23)

225 (84)

200 (61)

125 (38)

75 (23)

200 (61)

125 (38)

100 (31)

60 (18)

800 (244)

550 (168)

350 (107)

275 (84)

225 (69)

175 (53)

150 (46)

125 (38)

100 (31)

800 (244)

600 (183)

450 (137)

350 (107)

300 (91)

250 (76)

225 (69)

200 (61)

175 (53)

60 (18)

75 (23)

*Conductor size is based on maximum 2% voltage drop

OM-4409 Page 75

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SECTION 17 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING

gtaw_Phase_2007−04

Whenever possible and practical, use DC weld output instead of AC weld output.

17-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter

(DCEN) − Argon

AC − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

Balance Control @ 65% Electrode Negative

(For Use With Aluminum)

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens

.040” (1 mm)

1/16” (1.6 mm)

3/32” (2.4 mm)

1/8” (3.2 mm)

25-85

50-160

20-80

50-150

130-250

225-360

135-235

250-400

Pure Tungsten (Green Band)

.040” (1 mm)

1/16” (1.6 mm)

3/32” (2.4 mm)

1/8” (3.2 mm)

Pure Tungsten Not Recommended

10-60

50-100

100-160

150-210

For DCEN − Argon

♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

17-2. Preparing Tungsten Electrode For Welding With Phase Control Machines

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use

local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-

mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from

thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-

mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

A. Preparing Tungsten For DC Electrode Negative (DCEN) Welding

2-1/2 Times

Electrode Diameter

Grinding Wheel

Radial Grinding

Causes Wandering Arc

Grind end of tungsten on fine grit, hard

abrasive wheel before welding. Do not use

wheel for other jobs or tungsten can become

contaminatedcausing lower weld quality.

Tungsten Electrode

A 2% ceriated tungsten is recommended.

Flat

Diameter of this flat determines amperage

capacity.

Wrong Tungsten Preparation

Ideal Tungsten Preparation − Stable Arc

Straight Ground

Grind lengthwise, not radial.

Tungsten Electrode

A pure tungsten is recommended..

Balled End

B. Preparing Tungsten For AC Welding

1 − 1-1/2 Times

Electrode Diameter

Ball end of tungsten by applying AC amper-

age recommended for a given electrode

diameter(see Section 17-1). Let ball on end

of the tungsten take its own shape.

OM-4409 Page 76

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SECTION 18 − GUIDELINES FOR TIG WELDING (GTAW)

gtaw 7/2006

18-1. Positioning The Torch

Grinding the tungsten elec-

trode produces dust and fly-

ing sparks which can cause

injury and start fires. Use lo-

cal exhaust (forced ventila-

tion) at the grinder or wear an

approved respirator. Read

MSDS for safety information.

Consider using cerium or

lanthanum based tungsten

instead of thoriated. Tho-

rium dust contains low-level

radioactivematerial. Proper-

ly dispose of grinder dust in

an environmentally safe way.

Wear proper face, hand, and

body protection. Keep flam-

mables away.

90°

Workpiece

Make sure workpiece is clean

before welding.

Work Clamp

Place as close to the weld as

possible.

10−15°

Torch

Filler Rod (If Applicable)

Gas Cup

Tungsten Electrode

10−25°

Select and prepare tungsten

according to Section 17.

Guidelines:

The inside diameter of the gas cup

should be at least three times the

tungsten diameter to provide ade-

quate shielding gas coverage. (For

example, if tungsten is 1/16 in

diameter, gas cup should be a

minimumof 3/16 in diameter.

Tungsten extension is the distance

the tungsten extends out gas cup of

torch.

1/16 in

3/16 in

Bottom View Of Gas Cup

The tungsten extension should be

no greater than the inside diameter

of the gas cup.

Arc length is the distance from the

tungsten to the workpiece.

Ref. ST-161 892

OM-4409 Page 77

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18-2. Torch Movement During Welding

Tungsten Without Filler Rod

75°

Welding direction

Form pool

Tilt torch

Move torch to front

of pool. Repeat process.

Tungsten With Filler Rod

75°

15°

Welding direction

Form pool

Tilt torch

Add filler metal

Remove rod

Move torch to front

of pool. Repeat process.

ST-162 002-B

OM-4409 Page 78

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18-3. Positioning Torch Tungsten For Various Weld Joints

90°

Butt Weld And Stringer Bead

70°

20°

“T” Joint

70°

20°

10°

40°

Lap Joint

70°

20°

30°

90°

Corner Joint

70°

20°

ST-162 003 / S-0792

OM-4409 Page 79

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SECTION 19 − PARTS LIST

available unless listed.

11 12

133

148

147

123

132

146 − Figure 19-5

130

134

135

131 − Figure 19-2

136

138

139

140

124

125

145

126

137

127

141

143

128

129

142

144 − Figure 19-3

Figure 19-1. Main Assembly

OM-4409 Page 80

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150

151

113

114

115

116

102

117

118

101

112 − Figure 19-4

119

104

100

149

103

105

111

110

106

109

121

107

120

108

122

803 324

OM-4409 Page 81

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 19-1. Main Assembly

Quantity

. . . 1 . . . . . . . . . . . . . . 189824 . . Panel, Gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 189828 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . 206601 . . Panel, Engine Extension LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . Z1 . . . . . 208277 . . Reactor, AC Environmental Rda . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . CR7 . . ♦188636 . . Relay, OCV Control (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . ♦081499 . . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . . . . . . . . . . 038620 . . Link, Jumper Term Blk 30 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . 1T . . . . . 189549 . . Block, Term Assy Standard W/Clamp (includes) . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . . . . . . . . 038621 . . . . Block, Term 30 Amp 4 Pole Frict Term Str Both Side . . . . . . . . . . . . . . . 1

. . . 9 . . . . . . . . . . . . . . 081499 . . . . Bracket, Mtg Strip Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 138027 . . . . Edge Trim, Style Tl750−b2x1/16 Black W/Clips 3.750 . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 020225 . . . . Clamp, Nyl .875 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 1

. . . 10 . . SR4, SR5 . . 035704 . . Rectifier, Integ Bridge 40 Amp 800 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 11 . . . . CB4 . . . . 045061 . . Circuit Breaker, Auto Reset 24vdc 7 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . . . . . . . . 206352 . . Brace, Front To Center Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 13 . . . . . T1 . . . . . 205636 . . Transformer, W/Brkt Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . 201697 . . Pan, Reactor And Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . 173352 . . Extrusion, Rubber (order by ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . 189708 . . Firewall, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . 194485 . . Hose, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . . . 189764 . . Air Cleaner, Intake (Engine) (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *192938 . . . . Filter, Air Element Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *192939 . . . . Filter, Air Element Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 206556 . . Pipe, Air Cleaner Intake Deutz (Turbo Hose To Air Cleaner Hose) . . . . . 1

. . . 19 . . . . . . . . . . . . . . 189763 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . 206351 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Compressor) (includes) . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . 206696 . . Hose, Elbow Air Cleaner/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . . . 198457 . . Tube, Air Intake Perkins 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . 206697 . . Hose, Elbow Air Cleaner/Compressor 180 Degree . . . . . . . . . . . . . . . . . . . 1

. . . 28 . . . . . . . . . . . . . . 207268 . . Hose, Cwc Flexaust 2.000 Id X 22.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . +219140 . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . . 210151 . . Label, Air Cleaner Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . ♦209612 . . Lever, Switch Lockout Disconnect Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . ♦209597 . . Bracket, Mtg Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . ♦209611 . . Switch, Disc Battery 2P 6−36 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . . 196220 . . Bracket, Holddown Fuel Tank Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . . 192362 . . Bracket, Mtg Nyl 1/2 Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . +206603 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . . ♦143915 . . Mount, Sgl Stud 1.5 Dia X 1.000 Lg .312−18 Stud . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . ♦205702 . . Bracket, Mtg Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . ♦205749 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . ♦603767 . . Cap, Weather Exhaust No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . . . . . . . ♦010875 . . Clamp, Muffler 2.000 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 46 . . . . . . . . . . . . ♦205712 . . Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . . . . . . . . ♦205748 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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. . . 48 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . . . . . . . . . . . 213895 . . Manifold, Exhaust Muffler Bf4m2011 Deutz . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . . 202633 . . Support, Cover E−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 51 . . . . . . . . . . Figure 19-6 . . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . . 191577 . . Guard, Starter Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 53 . . . . . . . . . . . . . . 191809 . . Bracket, Mtg Engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . . . . . . . . . . . 209632 . . Hose, Tubing Oil Assyw/Fittings 22.380lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . . 218619 . . Engine, Deutz Dsl Elec Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 193256 . . . . Adapter, Engine Deutz 1011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 195748 . . . . Flywheel, Deutz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 195746 . . . . Sender, Coolant Temp & 130c Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 195745 . . . . Switch, Pressure Oil 1.5 Bar Nc Cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *067265 . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *066217 . . . . Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 208041 . . Spacer, Stl .323 Id X .625 Od X .141 Thk (Alternator) . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 193230 . . Sender, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 194403 . . Adaptor, Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . GLOW PLUG . 190059 . . Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . 207203 . . Fan, Engine Cooling 18.000 Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 208042 . . Spacer, Stl .800id X 1.188od X .090 Thk (Fan Hub Bolt) . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . *207808 . . Belt, V .375 X 45.125 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 209675 . . Extension, Hydraulic 37 Deg Flare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . . 209633 . . Hose, Tubing Oil Assyw/Fittings 27.040lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 60 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . . . 207269 . . Guard, Fan LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . . 206749 . . Shroud, Fan Air Pak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 63 . . . . . . . . . . . . . . 206558 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 64 . . . . . . . . . . . . . . 209623 . . Ftg, Brs Adapter Long 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 65 . . . . . . . . . . . . . . 201749 . . Upright, Rear Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 66 . . . . . . . . . . . . . . 201006 . . Bolt, J Stl .312−18 X 7.750 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 67 . . . . BATT . . . . 190897 . . Battery, Stor 12v 650 Crk 110 Rsv Gp 24 Maint Free . . . . . . . . . . . . . . . . 1

. . . 68 . . . . . . . . . . . . . . 108081 . . Terminal Protector, Battery Post Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 69 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1

. . . 71 . . . . . . . . . . . . . . 203430 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 72 . . . . . . . . . . . . . +201183 . . Cover, Battery Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 73 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 74 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 7

. . . 75 . . . . . . . . . . . . . +206602 . . Panel, Engine Extension R.H. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 76 . . . . . . . . . . . . . . 207270 . . Guard, Fan RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 77 . . . . . . . . . . . . . . 210229 . . Label, Compressor Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 78 . . . . . . . . . . Figure 19-6 . . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 79 . . . . . . . . . . . . . . 208024 . . Pulley, Fan Assy W/Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 80 . . . . . . . . . . . . . . 206613 . . Bracket, Mtg Fan/Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 81 . . . . . . . . . . . . . . 199849 . . Screw, 625−11x4.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 82 . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 83 . . . . . . . . . . . . . . 191812 . . Bracket, Mtg Engine R.h. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 84 . . . . . . . . . . . . . . 071890 . . Retainer, Mount Eng/Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 85 . . . . . . . . . . . . . . 071730 . . Tubing, Stl .875 Od X12ga Wall X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 86 . . . . . . . . . . . . . . 083476 . . Mount, Eng/Gen Nprn .875id X 2.500od X 2.000 60 Dur . . . . . . . . . . . . . . 4

. . . 87 . . . . . . . . . . . . . . 135205 . . Nut, 625−11 .94hex .77h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . 4

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Figure 19-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 88 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 89 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1

. . . 90 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.666

. . . 91 . . . . . . . . . . . . . . 176528 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 1/2 Npt . . . . . . . . . . . . . . . . . . . 1

. . . 92 . . . . . . . . . . . . . . 173336 . . Ftg, Adapter Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 93 . . . . . . . . . . . . . . 066298 . . Ring (Oil Drain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 94 . . . . . . . . . . . . . . 218003 . . Bracket, Mtg Fuel Filter/Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 95 . . . . . . . . . . . . . . 232968 . . Base, Fuel Filter Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 96 . . . . . . . . . . . . . *192744 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 199383 . . Hose, Sae .312 Id X .560 Od X 8.000 (Fuel Filter To Fuel Pump) . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 191819 . . Hose, Sae .312 Id X .560 Od X 14.000 (Fuel Tank To Fuel Filter) . . . . . . 1

. . . 97 . . . . . . . . . . . . . . 190992 . . Keeper, Latch Engine Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 98 . . . . . . . . . . . . . . 206604 . . Channel, Stiffener Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 99 . . . . . . . . . . . . . . 209093 . . Bracket, Safety Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 100 . . . . . . . . . . . . . 209092 . . Bracket, Mtg Saftey Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 101 . . . . . . . . . . . . . 174064 . . Idle, Solenoid Assy (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 196036 . . . . Bracket, Arm Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 125663 . . . . Ball Joint, .250−28 Type Sp Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 175936 . . . . Rod, Throttle 5.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 127994 . . . . Ball Joint, .250−28 Type Spf Female Rod End . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 127648 . . . . Clevis, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 124974 . . . . Solenoid, 12vdc Pull/Hold Type 1” Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 601868 . . . . Nut, 250−28 .44hex .26h Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 126388 . . . . Nut, 250−28 .44hex .27h Stl Pld Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 089800 . . . . Nut, 250−20 .44hex .22h Stl Pld .58d Flange Defor . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 108941 . . . . Screw, 250−20x1.00 Hexwhd.61d Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 156733 . . . . Nut, 250−28 .44hex .13h Stl Pld Sem Cone Wshr.51d . . . . . . . . . . . . . . 1

. . 102 . . . . . . . . . . . . . 209090 . . Bracket, Stiffener Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 103 . . . . . . . . . . . . +209089 . . Panel, Engine Access Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 104 . . . . . . . . . . . . . 206464 . . Label, Maintenance Big Blue Air Pak Deutz Ce . . . . . . . . . . . . . . . . . . . . . 1

. . 105 . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 106 . . . . . . . . . . . . . 210681 . . Handle, Pocket Pull Door Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 107 . . . . . . . . . . . . . 209091 . . Panel, Rocker Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 108 . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . 109 . . . . . . . . . . . . +189827 . . Panel, Gen Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 110 . . . . . . . . . . . . . 207448 . . Label, Maintenance I R Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 111 . . . . . . . . . . . . . 209059 . . Label, Schematic Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 112 . . . . . . . . . Figure 19-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 113 . . . . . . . . . . . . . 218087 . . Tank, Fuel (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 114 . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . 115 . . . . . . . . . . . . . 189912 . . . . Ftg, Stl Barbed Elbow W/.047in Orifice Zinc Pld . . . . . . . . . . . . . . . . . . . 1

. . 116 . . . . . . . . . . . . . 189909 . . . . Ftg, Stand Pipe Hose .250 X 9.265lg 90 Deg Zinc . . . . . . . . . . . . . . . . . 1

. . 117 . . . . . . . . . . . . . 189913 . . . . Ftg, Stl Barbed Elbow Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 118 . . . . . . . . . . . . . 190142 . . . . Sender, Fuel Gauge 9.750 Deep Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 119 . . . . . . . . . . . . . 189910 . . . . Ftg, Stand Pipe Hose .3125 X 9.260lg 90 Deg Zinc . . . . . . . . . . . . . . . . 1

. . 120 . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 121 . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 196219 . . Hose, Sae .250 Id X .500 Od X 26.000 (Fuel Return Line) . . . . . . . . . . . . 1

. . 122 . . . . . . . . . . . . . 191446 . . Extrusion, Rubber w/Adhesive 1.000 x 1.000 (order by ft.) . . . . . . . . . . . . 6ft

. . 123 . . . . . . . . . . . . . 209094 . . Bracket, Mtg Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 124 . . . . . . . . . . . . +212224 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 125 . . . . . . . . . . . . . 191897 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . 126 . . . . . . . . . . . . . 224266 . . Label, Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 127 . . . . . . . . . . . . . 206463 . . Label, Manufacturing Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 128 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 2

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Quantity

. . 129 . . . . R3 . . . . . 189699 . . Resistor, WW Tap 375 W 10 Ohm W/Mtg Bkt . . . . . . . . . . . . . . . . . . . . . . . 1

. . 130 . . . . . . . . . . . . . 218086 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 131 . . . . . . . . . Figure 19-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 132 . . . . . . . . . . . . . 189731 . . Firewall, Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 133 . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 134 . . . . . . . . . . . . . 191448 . . Cover, Top Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 135 . . . . . . . . . . . . . 206609 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 136 . . . . . . . . . . . . +206606 . . Box, Valve Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 137 . . . . . . . . . . . . . 209682 . . Label, Air Power Ingersoll−Rand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 138 . . . . . . . . . . . ♦039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 139 . . . . . . . . . . +♦207095 . . Box, Battery Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 140 . . . . . . . . . . . ♦039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 141 . . . . . . . . . . . ♦210156 . . Label, Battery Charge (Battery Charge +/−) . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 142 . . . . . . . . . . . . . 207096 . . Cover, Box Front Upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 143 . . . . . . . . . . . . . 209683 . . Label, Warning Safety Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 144 . . . . . . . . . Figure 19-3 . . Panel, Front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 145 . . . CT1 . . . . 202130 . . Xfmr, Current Sensing (Auto Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 146 . . . . . . . . . Figure 19-5 . . Main Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 147 . . . . . . . . . . . . . 193453 . . Bracket, Mtg Box Fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 148 . . . PC1 . . . . 207397 . . Module, Field Current Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 149 . . . . . . . . . . . . . 085963 . . Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) . . . . . . . . . . . 1

. . 150 . . . . . . . . . . . . . 105734 . . Pipe, Muffler Extension Elbow 1.750 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 151 . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1

. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . 206468 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . ♦195118 . . Kit, Lock-Out Vandalism (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦209238 . . . . Door, Access Rh W/Om Pocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦209240 . . . . Door, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦209236 . . . . Tab, Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦209241 . . . . Mount, Access Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦209242 . . . . Mount, Access Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦189975 . . . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . ♦155146 . . . . Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close . . . . . . . . . . . . 3

When ordering a component originally displaying a precautionary label, the label should also be ordered.

Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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803 325-D

Figure 19-2. Control Box Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-2. Control Box Assembly − (Figure 19-1 Item 131)

. . . 1 . . . F1, F2 . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 3 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 3

. . . 4 . . . . PC9 . . . . 192224 . . Circuit Card Assy, Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . . . . . . . . . 201077 . . Control Box, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 201078 . . Control Box, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . HM2 . . ♦145247 . . Meter, Hour Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . CR3,CR6 . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . CR8 . . . . 197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . CB15 . . . . 083432 . . Supplementary Protector, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . 1

. . . 11 . . . . CB8 . . ♦139266 . . Supplementary Protector, Man Reset 1p 15a 250vac Frict (Air Dryer) . . . 1

. . . 12 C8/D8,C10/D10 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 13 . . . . CR1 . . . . 214876 . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . CB14 . . . . 205927 . . Circuit Breaker, Auto Reset 12vdc 12 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . CB10 . . . . 190374 . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . CR5 . . . . 223710 . . Relay, Encl12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . CR14 . . ♦090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Air Dryer) . . . . . . . . 1

. . . 18 . . . . SR1 . . . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . PC7 . . . . 195706 . . Module, Pull To Idle, Two Output, 7 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . C1/D1 . . . . 189701 . . Diode/Capacitor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . C9 . . . . . 087110 . . Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . 177136 . . Clamp, Capacitor 1.375 Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Figure 19-2. Control Box Assembly (Continued)

. . . 23 . . . . . . . . . . . . . . 217823 . . Label, Layout Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . . . 201079 . . Cover, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . CR4, CR10 . 113247 . . Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg . . . . . . . . . . . . . . . . 2

. . . 26 . . . . TD1 . . . . 214928 . . Timer, Delay On Make/Break Open 30 Sec 12vdc . . . . . . . . . . . . . . . . . . . 1

. . . 27 CB11,CB12,CB13 139266 . . Supplementary Protector, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 217815 . . Harness, Engine Deutz Bf4m2011 (includes) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 156734 . . . . Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . S2 . . . . . 021467 . . . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 19-3) . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 211292 . . . . Conn, Body 5 Terminal (For Ignition Switch S1) . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . S10 . . . . 206624 . . . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Located On Front Panel, See Figure 19-3) . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 219873 . . Harness, Control Box, Weld Control LH (includes) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC3 . . . . 158466 . . . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . 1

. . . . . . . . . . RC1 . . . . 135133 . . . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 204737 . . . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . CR15 . . ♦172015 . . Time Delay Relay (Air Dryer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

♦Optional

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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not available unless listed.

803 326-A

Figure 19-3. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-3. Panel, Front w/Components (Figure 19-1 Item 144)

. . . 1 . . . . . . . . . . . . . . 217356 . . Plate, Screened Ident Control Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 215014 . . Panel, Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . S3 . . . . . 208278 . . Switch, Range/Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, Range Switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . RC6 . . . . 148389 . . . . Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . 1

. . . 4 . . . . . R1 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-3. Panel, Front w/Components (Continued)

. . . . . . . . . . . . . . . . . . . . 206809 . . Harness, Weld Control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . S6 . . . . . 193234 . . . . Switch, Rotary 6 Position Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197257 . . . . Guard, Circuit Breaker (For S6 − Not Included w/Harness) . . . . . . . . . . 1

. . . 6 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . 1

. . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG14 . . . 141450 . . . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 164617 . . . . Clip,Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . PLG10 . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . CB5 . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac Frict . . . . . . . . . . 1

. . . . . . . . . . CB6 . . . . 139266 . . . . Supplementary Protector, Man Reset 1p 15a 250vac Frict . . . . . . . . . . 1

. . . 8 . . . . . . . . . . . . . . 202209 . . Spacer, Nylon .221 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . PC6 . . . . 192995 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position W/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . S10 . . . . 206624 . . Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term (Included In Engine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 19-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . S2 . . . . . 021467 . . Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness, See Figure Figure 19-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . CB1 . . . . 201083 . . Supplementary Protector, Man Reset 2p 20a 250vac . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 201553 . . Clip, Retaining Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, Receptacle Auxillary Power (includes) . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . CB2 . . . . 093996 . . . . Supplementary Protector, Man Reset 1p 20a 250vac Frict . . . . . . . . . . 1

. . . 15 . . . GFCI1 . . . 151981 . . . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . RC1 . . . . 147632 . . . . Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 010146 . . . . Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole . . . . . . . . . . . . . 2

. . . 17 . . . . RC5 . . ♦182954 . . Rcpt, Str 3p4w 50a 125/250v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . ♦025248 . . Stand-off, Insul .250-20 X 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . ♦604102 . . Connector, Clamp Cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . ♦197527 . . Guard, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . ♦197363 . . Terminal, Ring Tng Screw Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 22 . . . . CB7 . . ♦214926 . . Supplementary Protector, Man Reset 3p 50a 250vac . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . +215347 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . +♦215363 . . Panel, Generator Power (Full KVA Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . CT2 . . ♦197433 . . Transformer, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . ♦214927 . . Boot, Circuit Breaker 1 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . ♦197508 . . Plug, Protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . ♦077440 . . Bushing, Conduit 1 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . 163167 . . Washer, Lock .254idx0.489odx.062t Sst Split.250 . . . . . . . . . . . . . . . . . . . 2

. . . 28 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . ♦209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . . 190861 . . Label, Warning Electric Shock And Moving Parts Etc . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦197399 . . Label, Warning 3 Ph Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle 2.250 Dia. Lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 32 . . . . . . . . . . . . ♦210149 . . Label, Battery Charge (Switch Position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . ♦ . . Label, Polarity/AC Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . S12 . . ♦220491 . . Switch, Polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S13 . . ♦210217 . . Switch, Battery Charge Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . . 201125 . . Panel, Mtg Terminal Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . PC4, PC5 . . 189744 . . Circuit Card Assembly, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 36 . . . . . . . . . . . . ♦210206 . . Bracket, Support Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 38 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 8

. . . 39 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 40 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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Figure 19-3. Panel, Front w/Components (Continued)

. . . 41 . . . . . . . . . . . . ♦059773 . . Switch, Handle (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . ♦010647 . . Pin (Polarity/AC Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦059773 . . Handle, Switch (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦010647 . . Pin,Spring Cs .156 X 1.250 (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦081499 . . Bracket, Mtg Strip Terminal (Battery Charging) . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 46 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . HM1 . . . . 210424 . . Meter, Hour 12−24vdc (Snap−in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 48 . . . . FUEL . . . . 192265 . . Gauge, Fuel Elec Switch W/O Switchgage Sensor . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . BAT . . . . 193228 . . Meter, Volt DC 8 − 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . AIR . . . . 206599 . . Gauge, Pressure 0−200 Psi Electric Switch . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 51 . . . . TEMP . . . 217084 . . Gauge, Engine Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . OIL . . . . . 217083 . . Gauge, Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 53 . . . . . A1 . . . ♦164873 . . Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . CT3 . . ♦209274 . . Xfmr, Current (Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . V1 . . . ♦164874 . . Meter, Volt AC/DC 0− 100 Scale 2.5 In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . 189161 . . Handle, Switch Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 010647 . . Pin, Spring Cs .156 X 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . . 097924 . . Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 215207 . . Harness, Unit Weld Control − CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG6 . . . . 114063 . . . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG8 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG13 . . . 158465 . . . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 088731 . . . . Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 135873 . . . . Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 187654 . . . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 196602 . . . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . 7

. . . . . . . . . . . . . . . . . . . . 059712 . . Clip, Component .437 Dia Mtg Adh Back . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 024103 . . Blank, Snap−in Nyl .750 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 120304 . . Blank, Snap−in Nyl .250 Mtg Hole Black . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 025234 . . Plug, Str Grd 2p3w 15a 250v *6−15p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

♦Optional

When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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Figure 19-4. Generator

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Figure 19-4. Generator (Figure 19-1 Item 112)

Quantity

. . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 2 . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs . . . . . . . . . . . . . . . . . 6

. . . 3 . . . . . . . . . . . . . . 195911 . . Endbell, Gen (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . 143220 . . . . O-Ring 2.859 ID X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . AUX STATOR . 201099 . . Stator, Exciter/Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . STATOR . . +208287 . . Stator, Weld Assy Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . STATOR +♦209220 . . Stator, Weld Assy Complete (3-Phase Generator Option) . . . . . . . . . . . . . 1

. . . 7 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Serious . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . . . . . . . . 190197 . . Guard, Generator Wire Mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . . . . . . . . . . . 172674 . . Spring, Ext .240 Od X .041 Wire X 3.500 Pld . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 10 . . . . . . . . . . . . . . 039207 . . Baffle, Air Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . ROTOR . . . 212997 . . Rotor, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . . . . . . . . 024617 . . . . Ring, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 210447 . . . . Fan, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hub, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . 210332 . . . . . . Plate, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . 206242 . . . . . . Fan, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 16 . . . . . . . . . . . . . . 049026 . . . . . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 10

. . . 17 . . . . . . . . . . . . . . 083883 . . . . . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . 10

. . . 18 . . . . . . . . . . . . . . 080389 . . . . . . Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . 8

. . . 19 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 4

. . . 20 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 21 . . . . . . . . . . . . . . 191579 . . Cover, Starter Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 6

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Figure 19-4. Generator (Continued)

. . . 23 . . . . . . . . . . . . . . 172555 . . Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 24 . . . . . . . . . . . . . . 602159 . . Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . . . . . . . 6

. . . 25 . . . . . . . . . . . . . . 604950 . . Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 26 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 4

. . . 27 . . . . . . . . . . . . . . 139341 . . Washer, Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 28 . . . . . . . . . . . . . *190823 . . Brush, Contact Elect .250 X.500 X 1.250 Grd Ay . . . . . . . . . . . . . . . . . . . . 3

. . . 29 . . . . . . . . . . . . . . 188560 . . Clip, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 30 . . . . . . . . . . . . . . 189142 . . Brushholder Assy, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . . 602242 . . Washer, Flat .375idx0.875odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 32 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 2

. . . 33 . . . . . . . . . . . . . . 604534 . . Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 2

When ordering a component originally displaying a precautionary label, the label should also be ordered.

*Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

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not available unless listed.

802 279-A

Figure 19-5. Main Rectifier Assembly

Item

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Part

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Description

Quantity

Figure 19-5. Main Rectifier Assembly (Figure 19-1 Item 146)

. . . . . . . . . . SR3 . . . . 215910 . . Rectifier, environmental (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . . . 188137 . . . . Connection Board, Rectifier Ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 188517 . . . . Bus Bar, Conn Bd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 3 . . . . . . . . . . . . . . 188135 . . . . Enclosure, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 4 . . . . . . . . . . . . . . 134201 . . . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . 3

. . . 5 . . . . PC3 . . . . 215755 . . . . Circuit Card Assy, Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 188136 . . . . Insulator, Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . 7 . . . . . . . . . . . . . . 188493 . . . . Heat Sink, Rectifier Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 8 . D3, D5, D7 . 208334 . . . . Diode, Rect 275. A 300v Sp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 9 . D2, D4, D6 . 208335 . . . . Diode, Rect 275. A 300v Rp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4409 Page 93

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not available unless listed.

803 328−G

Figure 19-6. Air Compressor Assembly

OM-4409 Page 94

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Item

No.

Dia.

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Part

No.

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Quantity

Figure 19-6. Air Compressor Assembly (Figure 19-1 Item 78)

. . . 1 . . . . . . . . . . . . . . 206607 . . Valve, Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 210523 . . Ftg, Flrd Stl Tube End/Female Pipe End 3/4 . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . 206939 . . Tank, Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . 210248 . . Hose Assy, Air W/Fittings 3/4 X 35.250 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 5 . . . . . . . . . . . . . . 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 117826 . . Ftg, Pipe Brs Nipple Close 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 7 . . . . . . . . . . . . . . 210053 . . Valve, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . . . . . . . . . . 071270 . . Ftg, Pipe Brs Tee St 1/4 Npt 071 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . . . . . . . . . . . 209854 . . Ftg, Pipe Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 10 . . . . . . . . . . . . . . 218602 . . Hose, Nylon Blue 44.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . . . . . . . . . . 210040 . . Orifice/Muffler,120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 12 . . . . . . . . . . . . . . 151662 . . Ftg, Pipe Brs Plug Hex .125 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . 218601 . . Hose, Nylon Red 36.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . 210054 . . Valve, Automatic Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . 206746 . . Switch, Pressure 20psi Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . 602965 . . Ftg, Pipe Brs Tee 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . 209635 . . Hose, Assy w/Fittings 42.360lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . 210051 . . Valve, Check Minimum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . 209767 . . Ftg, Pipe Stl Connector M 3/4 Sae−npt Adapter . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . . . 206615 . . Sender, Pressure Oil 0− 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . 073655 . . Ftg, Pipe Brs Nipple Hex 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . 206937 . . Manifold, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . . . . . . . . . . . . 206743 . . Valve, Safety Relief 150psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . 209754 . . Ftg, Pipe Stl Elbow M 45dg 3/4 X (Npt−jic 45dg) . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . . . 214685 . . Hose Assy, Air W/Fittings 3/4 X 21.750 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . 209787 . . Ftg, Pipe Stl Nipple Close 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 28 . . . . . . . . . . . . . . 209621 . . Fitting, Stl Adapter 3/4 SAE − 3/4 JIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . . 210058 . . Gauge, Oil Level Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 31 . . . . . . . . . . . . . . 209766 . . Ftg, Pipe Stl Tee Street 3/4 Npt M−f−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . . . 209457 . . Ftg, Pipe Stl Elbow St 3/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 33 . . . . . . . . . . . . . . 209638 . . Hose, Oil W/Fittings 25.670 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . . 209639 . . Hose, Oil W/Fittings 26.320 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . . 210254 . . Bracket, Mtg Tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . . 210251 . . Ftg, Stl Swivel Straight Thread Conn 3/4 O−ring . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . 210252 . . Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . . . . . . . . . . . 210250 . . Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . . 209765 . . Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−jic− . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . . . . 208040 . . Tensioner,Belt w/Pully . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . . . . 208428 . . Idler Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . . . 225038 . . Bracket, Mtg Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . . . 206742 . . Switch, High Air Temperature 248f Nc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 210022 . . O−ring, High Air Temp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . 211904 . . Manifold, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 218558 . . Screw, M 8−1.2x 50 Hex Hd−pln 8.8 Pld (Manifold Mtg.Screws) . . . . . . . 4

. . . 45 . . . . . . . . . . . . . . 209641 . . Hose, Nylon White 32.000lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . . 209855 . . Ftg, Pipe Stl Adapter M 1/8 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 47 . . . . . . . . . . . . . . 015732 . . Ftg, Pipe Brs Elbow St 45 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 48 . . . . . . . . . . . . . . 209852 . . Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 49 . . . . . . . . . . . . . . 225005 . . Brace, Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . . 084999 . . Ftg, Pipe Brs Elbow St 45 1/4 NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 51 . . . . . . . . . . . . . . 176518 . . Ftg, Pipe Brs Elbow St 1/4 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 52 . . . . . . . . . . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Figure 19-5. Air Compressor Assembly (Continued)

. . . 53 . . . . . . . . . . . . . . 206698 . . Plate, Mtg Compressor To Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 54 . . . . . . . . . . . . . . 218305 . . Valve, Inlet Unloader 90dg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 210016 . . Gasket, Unloader Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . CLUTCH . . 210055 . . Clutch, Electro Magnetic 12vdc W/5.75 Dia Pulley . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . 218609 . . Belt, Micro V 21mm X 1485mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . 206800 . . Pulley, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 210001 . . Airend, Gear−driven W/Tapered Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . . . 209853 . . Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 60 . . . . . . . . . . . . . . 209634 . . Hose, Tubing Oil Assyw/Fittings 15.860lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . . . 206558 . . Cooler, Oil Engine/Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . . 209851 . . Ftg, Pipe Stl Tube End Cap 3/4 0rfs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 63 . . . . . . . . . . . . . . 209825 . . Ftg, Stl Adapter Swivel 12m X Jic−12 F . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 64 . . . . . . . . . . . . . . 209764 . . Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 65 . . . . . . . . . . . . . . 209828 . . Ftg, Stl Swivel Union Jic−12 F−f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 66 . . . . . . . . . . . . . . 209621 . . Ftg, Stl Adapter 3/4 Sae−3/4 Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 67 . . . . . . . . . . . . . . 210052 . . Valve,Oil Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 68 . . . . . . . . . . . . . . 206744 . . Thermostat, 170f (w/gasket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 69 . . . . . . . . . . . . . . 206745 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . . 209756 . . Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 71 . . . . . . . . . . . . . . 214686 . . Ftg, Pipe Stl Elbow 90dg 3/4bspt M X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . 1

. . . 72 . . . . . . . . . . . . . . 210023 . . Filter, Separator Assembly (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 73 . . . . . . . . . . . . . . 206747 . . . . Separator, Oil/Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 74 . . . . . . . . . . . . . . 208029 . . Bracket, Mtg Filter Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 75 . . . . . . . . . . . . . . 209646 . . Tubing, Ssstl .312 Od X.028 W/Ftgs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 76 . . . . . . . . . . . . . . 209856 . . Ftg, Stl Adapter Tube End Reducer 04f X 05m . . . . . . . . . . . . . . . . . . . . . . 1

. . . 77 . . . . . . . . . . . . . . 210027 . . Valve, Check/Scavenge Orifice/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 78 . . . . . . . . . . . . . . 209755 . . Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *210056 . . Oil, Compressor 1gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 79 . . . . . . . . . . . . . . 044772 . . Screw, M12−1.7x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 80 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 6

. . . 81 . . . . . . . . . . . . . . 198447 . . Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 82 . . . . . . . . . . . . . . 602243 . . Washer, Flat .438idx1.000odx.083t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 83 . . . . . . . . . . . . . . 208425 . . Screw, M10−1.5x 60 Hex Hd−pln 8.8 Pld Din 931 . . . . . . . . . . . . . . . . . . . . 1

. . . 84 . . . . . . . . . . . . . . 198631 . . Nut, M10 Hex Lock Nut Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 85 . . . . . . . . . . . . . . 208426 . . Screw, M12−1.75x 40 Hex Hd 12pt Flange Screw 12.9 . . . . . . . . . . . . . . . 2

. . . 86 . . . . . . . . . . . . . . 602216 . . Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 . . . . . . . . . . . . . . . . . 2

. . . 87 . . . . . . . . . . . . . . 214687 . . Ftg, Pipe Stl 3/4bspp X 3/4 Jic M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 88 . . . . . . . . . . . . . . 214920 . . Seal, Ring Bonded Rbr/Stl .950 Id X 1.380 Od X .100 . . . . . . . . . . . . . . . . 1

. . . 89 . . . . . . . . . . . . . . 218423 . . O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-4409 Page 96

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Effective January 1, 2007

(Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Warranty Questions?

LIMITED WARRANTY − Subject to the terms and conditions

below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to

its original retail purchaser that new Miller equipment sold after

the effective date of this limited warranty is free of defects in

material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

APT & SAF Model Plasma Cutting Torches

Remote Controls

Call

1-800-4-A-MILLER

for your local

Miller distributor.

Accessory (Kits)

Replacement Parts (No labor)

Spoolmate Spoolguns

Canvas Covers

Within the warranty periods listed below, Miller will repair or

replace any warranted parts or components that fail due to such

defects in material or workmanship. Miller must be notified in

writing within thirty (30) days of such defect or failure, at which

time Miller will provide instructions on the warranty claim

procedures to be followed.

Your distributor also gives

you ...

Miller’s True Blue® Limited Warranty shall not apply to:

Service

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays

or parts that fail due to normal wear. (Exception:

brushes, slip rings, and relays are covered on Bobcat,

Trailblazer, and Legend models.)

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

Miller shall honor warranty claims on warranted equipment listed

below in the event of such a failure within the warranty time

periods. All warranty time periods start on the delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped to

an International distributor.

2. Items furnished by Miller, but manufactured by others, such

as engines or trade accessories. These items are covered

by the manufacturer’s warranty, if any.

Support

Need fast answers to the

tough welding questions?

Contact your distributor.

The expertise of the

distributor and Miller is

there to help you, every

step of the way.

3. Equipment that has been modified by any party other than

Miller, or equipment that has been improperly installed,

improperly operated or misused based upon industry

standards, or equipment which has not had reasonable and

necessary maintenance, or equipment which has been

used for operation outside of the specifications for the

equipment.

1. 5 Years Parts — 3 Years Labor

Original main power rectifiers

2. 3 Years — Parts and Labor

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Process Controllers

Semi-Automatic and Automatic Wire Feeders

Inverter Power Sources (Unless Otherwise Stated)

Water Coolant Systems (Integrated)

Intellitig

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND

USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS

TRAINED AND EXPERIENCED IN THE USE AND

MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the

exclusive remedies shall be, at Miller’s option: (1) repair; or (2)

replacement; or, where authorized in writing by Miller in

appropriate cases, (3) the reasonable cost of repair or

replacement at an authorized Miller service station; or (4)

payment of or credit for the purchase price (less reasonable

depreciation based upon actual use) upon return of the goods at

customer’s risk and expense. Miller’s option of repair or

replacement will be F.O.B., Factory at Appleton, Wisconsin, or

F.O.B. at a Miller authorized service facility as determined by

Miller. Therefore no compensation or reimbursement for

transportation costs of any kind will be allowed.

3. 1 Year — Parts and Labor Unless Specified

Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

Positioners and Controllers

Automatic Motion Devices

RFCS Foot Controls

Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

Water Coolant Systems (Non-Integrated)

Flowgauge and Flowmeter Regulators (No Labor)

HF Units

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

Grids

ANY

IMPLIED

WARRANTY,

GUARANTY

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION

OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

Spot Welders

Load Banks

Arc Stud Power Sources & Arc Stud Guns

Racks

Running Gear/Trailers

Plasma Cutting Torches (except APT & SAF

Models)

Field Options

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)

Bernard-Branded Mig Guns (No Labor)

Weldcraft-Branded TIG Torches (No Labor)

Subarc Wire Drive Assemblies

Some states in the U.S.A. do not allow limitations of how long an

implied warranty lasts, or the exclusion of incidental, indirect,

special or consequential damages, so the above limitation or

exclusion may not apply to you. This warranty provides specific

legal rights, and other rights may be available, but may vary from

state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations and

exclusions set out above may not apply. This Limited Warranty

provides specific legal rights, and other rights may be available,

4. 6 Months — Batteries

5. 90 Days — Parts

MIG Guns/TIG Torches and Subarc (SAW) Guns

but may vary from province to province.

miller_warr 2007−01

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Owner’s Record

Please complete and retain with your personal records.

Model Name

Purchase Date

Distributor

Address

Serial/Style Number

(Date which equipment was delivered to original customer.)

City

State

Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

Replacement Parts

Training (Schools, Videos, Books)

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

Welding Process Handbooks

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

www.MillerWelds.com

Contact the Delivering Carrier to:

File a claim for loss or damage during

shipment.

For assistance in filing or settling claims, contact

your distributor and/or equipment manufacturer’s

Transportation Department.

PRINTED IN USA

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