Download Miller Electric Big Blue 401DXQ Specifications
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DM173 413C January 1997 Eff. w/Serial Number KG214633 Miller. Processes Stick The Power ofBlue. TIG (SMAW) Welding (GTAW) Welding (CAC-A) Cutting ~ Air Carbon Arc With Optional Equipment: and Gouging Flux Cored (FCAW) Welding Description Engine Driven Welding Generator ct Big Blue 401 DXQ (~L~ 'OPY ~J~T) FOL~ 0 Il Visit our website at w.MU1erWe~$S~Crn1~ OWNERS MANUAL Call 1 -800-4-A-MILLER for your local Miller distrihutor. TABLE OF CONTENTS SECTION 1 EMF Information 1-4. Service You always get fast, the reliable response you need. Most replacement SECTION 1 1-1. be in your hands in 24 hours. parts can 1-2. 1-3. Support 1-4. Need fast answers to the Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical contact your local distributor. Your distributor Manual, Welding supply you with Process Manuals suchasSMAW, GTAW, GMAW, and GMAW-P For practical information Principales normes 1-6. Information sur our Diesel exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. engine 2-3. Symbols And Definitions 13 SPECIFICATIONS 14 12 Weld, Power, And Engine Specifications 14 3-2. Dimensions, Weights, And Operating Angles Duty Cycle And Overheating 14 15 3-5. Volt-Ampere Curves AC Auxiliary Power 3-6. Fuel 3-3. 3-4. 15 16 Consumption 16 SECTION 4INSTALLATION 17 4-4. Installing Welding Generator Activating The Dry Charge Battery Connecting The Battery Engine Prestart Checks 4-5. Installing Pipe 20 4-6. Connecting To Weld Output Terminals Selecting Weld Cable Sizes 20 4-3. 4-7. Muffler 17 18 19 19 THE WELDING GENERATOR 21 22 5-1. Front Panel Controls 22 5-2. Manual Shutoff Lever 23 5-3. Remote NV Control 6-1. 23 AUXILIARY EQUIPMENT 120 Volt And 240 Volt Duplex Receptacles Optional Auxiliary Power Receptacles SECTION 7 MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance 7-2. Maintenance Label 7-3. Servicing 7-4. Oil And Fuel 24 24 25 26 26 27 Air Cleaner 28 System Components Adjusting Engine Speed 29 7-5. 7-6. Overload Protection 31 7-7. Optional Spark Arrestor Inspection And Cleaning Troubleshooting 31 30 32 SECTION 8 ELECTRICAL DIAGRAM 34 SECTION 9 RUN-IN PROCEDURE 35 8-1. Wetstacking 8-2. Run-In Procedure 8-3. Run-In WARRANTY = 9 Label For CE Products 3-1. SECTION 10 = 9 Rating 7-8. The following terms are used interchangeably throughout this manual: Stick SMAW TIG GTAW 8 Manufacturers 6-2. 65 6 le fonctionnement 8 champs Ølectromagnetiques Label Definitions SECTION 6OPERATING Proposition Warning 5 7 de sØcuritØ DEFINITIONS SECTION 5OPERATING CALIFORNIA 5 2-2. website at www.MlHerWetds.com les 5 Warning 4-2. welding, process applica tions, and Miller products, visit LIRE AVANT UTILISATION 2-1. 4-1. on 4 des 1-5. SECTION 3 can SECtJRITE symboles Dangers relatits au soudage a Iarc Dangers existant en relation avec le moteur Dangers supplØmentaires en relation avec linstallation, SECTION 2 3 4 CONSIGNES DE Signification 2 And Maintenance et Ia maintenance tough welding questions? also READ BEFORE USING 1-6. 1-3. gives you - 1-5. 1-2. Your distributor SAFETY PRECAUTIONS Symbol Usage Arc Welding Hazards Engine Hazards Additional Symbols For Installation, Operation, Principal Safety Standards 1-1. Using Load Bank Procedure Using Resistance PARTS LIST 35 36 Grid 37 38 Conformity for European Community (CE) Products Declaration of NOTE This in formation is provided for units with CE certification ~ Manufacturers Name: M ill e r Electric M fg. Co. Manufacturers Address: 1635 W. Declares that the con forms to the WI 54914 USA B j g B I u efi 401 DXQ product: following Street Spencer Appleton, (see rating label on unit). Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC,91 /368/EEC, 93/C 133/04, 93/68/EEC Noise Emission Directive: 79/113/EEC Noise level of Welding Electromagnetic compatibility Generators: 84/535/EEC Directives: 89/336/EEC, 92/31/EEC Standards Safety Requirements Rotating Rotating for Arc Electrical Machines Electrical Machines Welding Equipment Part 1: Rating Part 1: EN 60974-1: 1990 and Performance: IEC 34-1: 1994 Part 5: Classification of electrical machines degrees of protection provided by (IP code): IEC 34-5: 1991 enclosure of rotating Insulation coordination for Part 1: equipment within low-voltage systems: Principles, requirements and test: IEC 664-1: 1992 Electromagnetic compatibility (EMC) Product European Contact: Mr. standard for Luigi Vacchini, Managing Europe S.P.A. MILLER Via Privata Iseo 20098 San Giuliano Milanese, Italy Telephone: Fax: dec_coni 1/96 39(02)98290-1 39(02)98281-552 arc welding equipment: Director EN5O1 99: August 1995 SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING rorn 1-1. SyrnbolUsge Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. a A Marks 1-2 not safety related. Welding Hazards Arc The This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. special safety message. a ~T Means ~Note A shown below symbols to call attention to and are used throughout this manual identify possible hazards. When you symbol, watch out, and follow the related instructions safety information given below is only a summary of the more complete safety Information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. see the Use only well-maintained equipment. Repairor replace damaged at once. Maintain unit according to manual. parts safety harness Wear a Keep all to avoid the hazard. The A Only qualified persons should Install, operate, maintain, repair this unit. A _nd_5/97 and Clamp or panels and clamp when contact with any metal During operation, keep everybody, especially children, away. good above floor level. securely in place. metal-to-metal contact to the weld as near Insulate work working covers work cable with worktable if as workpiece practical. not connected to workpiece to prevent object. Do not connect more than one electrode weld output terminal. or work cable to any single ELECTRIC SHOCK live Touching can electrical parts kill can ARC RAYS cause burn eyes and skin fatal Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all circuits can that can bum eyes and skin. Sparks fly off from the weld. are touching the welding wire are electrically live. Incorrectly improperly grounded equipment is a hazard. metal parts installed or Wear Do not touch live electrical parts. Wear Wear a welding helmet fitted with a proper shade offilterto 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). approved safety glasses with side shields under your helmet. dry, hole-free insulating gloves and body protection. yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Insulate Do not use AC output in damp areas, if movement is confined, a danger of falling. or Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant (wool and leather) and foot protection. material if there is output ONLY Use AC If AC output is unit. if required, use remote output control if present on or stop engine before installing or Lockout/tagout input power according CFR 1910.147 (see Safety Standards). Disconnect input power this equipment. servicing to OSHA 29 Properly Owners install and ground this equipment according to its Manual and national, state, and local codes. Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When making input connections, conductor first attach proper grounding double-check connections. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. Turn off all equipment when Do not worn, use drape If earth grounding a cables separate use. damaged, undersized, Do not with not in over your or poorly spliced cables. body. of the workpiece is required, ground it directly cable do not use work clamp or work cable. Do not touch electrode if you are in contact with the work, or another electrode from a different machine. FUMES AND GASES can be hazardous ~ required for the welding process. ground, Welding produces fumes these fumes and gases health. and gases. Breathing be hazardous to your can ____________ Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or remove welding fumes and gases. If ventilation is poor, Read the Material manufacturers use an use exhaust at the arc to approved air-supplied respirator. Data Sheets (MSDS5) and the instructions for metals, consumables, coatings, Safety cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-173 413 Page 1 HOT PARTS WELDING can cause fire or explosion on drums, pipes, can hot Allow cooling period before maintaining. protective gloves and clothing when working on a hot engine. Do not touch hot engine parts or just-welded closed containers, such as tanks, can cause them to blow up. Sparks off from the welding arc. The flying sparks, Welding or fly workpiece, and hot equipment Wear fires can cause and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before parts bare-handed. doing any welding. NOISE yourself Protect and others from Do not weld where flying sparks strike flammable material. can possible, tightly (10.7 m) of the welding arc. them with approved covers. cover can and hot metal. flying sparks Remove all flammables within 35 ft this is not Noise from Wear welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and that aware fire can cause keep welding on a fire I I partition or some approved unless they on the hidden side. closed containers such are as tanks, drums, properly prepared according or pipes, (see to AWS F4.1 Safety Standards). unknown Do not to and as causing ~ going cut off or protective garments welding wire such as leather a H keep away. welding, gouging, arc ....ERS or spot lighter or matches, process, be Injure eyes. excessive heat, compressed gas cylinders slag, open flames, sparks, and arcs. or an cylinder upright position by securing to prevent falling or tipping. a stationary rack to Keep cylinders away from any welding or other electrical circuits. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. Never drape Never allow Never weld Use only injure or kilt.~ a a welding torch over a on a pressurized cylinder will result. shielding gas cylinders, regulators, hoses, for the specific application; maintain them parts in good condition. and and Turn face away from valve outlet when in connected for shielding gas supply when not in use. use or Always ventilate confined spaces or use Read and follow instructions associated opening cylinder valve. place over valve except when cylinder is in Shut off ap cylinder. explosion fittings designed Keep protective cap proved air-supplied respirator. cylinder. gas to touch any welding electrode correct associated OF GAScan. carefully. mechanical shocks, Install cylinders in can to treat them sure from Protect support FLYING METAL explode if darnaged~ gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding gloves, heavy 1 ~BUILDUP. can Shielding at cap. Remove any combustibles, such as a butane from your person before doing any welding. use. equipment, compressed gas cylinders, publication P-i listed in Safety on and CGA Standards. 14: Engine Hazards FUEL : can cause Stop engine and or adding fuel. tire or .:,. STEAM AND HOT COOLANT expIosIon~ let it cool off before Do not add fuel while smoking sparks or open flames. or if unit is Do not overfill tank spill fuel. Dispose of rags in Page 2 allow If fuel is a room spilled, fireproof for fuel to If the near container. engine is warm and checking burn engine is is needed, follow the next two statements. expand. clean up before can If possible, check coolant level when cold to avoid scalding. checking any OM-173 413 near pipes. shirt, cuffless trousers, high shoes, and Do not wearers ers welding area as traveling long, possibly electric shock and fire hazards. Remove stick electrode from holder tip when not in use. ~ protection if noise level is Wearers should consult their doctor before contact I ear close to the current from welder to thaw frozen Wear oil-free can welding operations. prevent welding paths use equipment ____________ Connect work cable to the work practical or MAGNET CflELDScanaftectpace Pacemaker Do not weld processes high. extinguisher nearby. ceiling, floor, bulkhead, on a damage hearing. damage hearing. If Be alert that Be bums can cause severe starting engine. Wear Turn safety glasses and gloves and put and cap slightly completely removing cap. let pressure a rag over escape radiator cap. slowly before MOVING PARTS BAT~ERV ACID Injury cart cause Do not Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Stop engine before installing only qualified people and troubleshooting Have or connecting guards remove enance as tip battery. Replace damaged battery. Reinstall panels or finished and before with water. unit. or covers for maint necessary. LUST GASES prevent accidental starting during servicing, disconnect negative () battery cable from battery. loose immediately Flush eyes and skin To Keep hands, hair, parts. EYES~ BURN SKIN and can and tools away from clothing, guards and close starting engine. doors when moving servicing is ~ Use in outside equipment ventilated kill can well- open, areas. engine exhaust building air in If used in a closed area, vent outside and away from any takes. Before working on generator, remove spark plugs or injectors to keep engine from kicking back or starting. Block flywheel that it will not turn while so working on generator components. ENGINE HEAT Do can cause locate not unit combustible surfaces BATrERY EXPLOSION can BU ND. Keep exhaust on, or tire or over, near flammables. and exhaust pipes way from flammables. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connect ing battery cables or servicing battery. Do not allow tools to Do not use welder to Observe correct Disconnect 1-4. cause sparks charge batteries polarity (+ and ) on or working jump on a battery. start vehicles. batteries. EXHAUST SPARKS fire can cause engine exhaust sparks cause fire. approved engine exhaust spark arrestor required areas see applicable codes. Do not let Use in cable first and connect it last. negative () Symbols For InstaItat~on, Operation, And Maintenance AddlUonal EALLK~G UNIT Use when lifting eye can casŁ to lift unit OVERUSE Injury~ only, NOT running Allow can cause OVERHEATING cooling period; follow rated duty cycle. ________ trailer, gear, gas cylinders, accessories. or any other starting Use equipment of adequate capacity to lift and support unit. If Reduce current using lift forks to move unit, be sure forks beyond opposite side of unit. are long enough to weld Do not block or reduce or duty cycle before again. filter airflow to unit. to extend STATIC Put (ESD} can damage on handling FLYING SPARKS Wear a can cause face shield to Injury can cause fires Use proper store, move, or wrist strap BEFORE parts. static-proof bags and or ship PC boards. boxes to protect eyes and face. Shape tungsten electrode only on grinder with proper guards in a safe location wearing prop er face, hand, and body protection. Sparks grounded boards PC boards keep flammables away. TILTING OF TRAILER Use tongue jack or can cause blocks to Injury support weight. Properly install welding generator onto trailer according to instructions supplied with trailer. OVERHEATING can damagemotors. unplug equipment before starting or stopping engine. Do not let low voltage and frequency caused by low engine speed damage electric motors. Turn off or Do not connect 50 tacle where or 60 Hertz motors to the 100 Hertz recep applicable. READ INSTRUCTIONS only genuine MILLER replacement parts. engine maintenance and service according to this manual and the engine Use Perform manual. OM-173 413 Page 3 H F RADIATION can cause Interference ARC WELDING High-frequency (HF.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. such To reduce possible, If notified by at once. the FCC about interference, Have the installation stop using the and maintained. Be area is possible interference, keep weld cables as short as together, and down low, such as on the floor. close welding operation equipment. sure according 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. this 100 meters from any sensitive elec welding machine is installed and grounded to this manual. If interference still occurs, the user must take extra measures as moving the welding machine, using shielded cables, such using I .5 computer-driven equipment and robots. Locate tronic regularly checked as Be sure all equipment in the welding electromagnetically compatible. is equipment energy can interfere with electronic equipment such as computers installation. user Interference Electromagnetic sensitive responsible for having a qualified electrician promptly correct any interference problem resulting from the The can cause line filters, or shielding the work area. Pnnclpal Safety Standards and Cutting, ANSI Standard Z49.1, from American 550 N.W. LeJeune Rd, Miami FL 33126 of Compressed Gases Safety in Welding Safe Welding Society, P-i, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-6 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 committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard. However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when To in Cylinders, CGA Pamphlet Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And NFPA Standard 51 B, from National Association, Batterymarch Park, Quincy, MA 02269. Welding Processes, Fire Protection EME Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields cutting. reduce magnetic welding Handling or OM-173 413 Page fields in the workplace, use the following Keep 2. Arrange cables 3. Do not coil 4. Keep welding power source and cables operator as practical. 5. Connect work 4 or together by twisting or taping them. to one side and away from the drape cables clamp to around your workpiece as operator. body. as far away from close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor first. If cleared by your doctor, following the above procedures is recommended. then procedures: cables close 1. SECTION 1 - CONSIGNES DE SECURITE UTI LISATION - LIRE AVANT rom ~1-1 Signification symboles Signifie Mise en garde! Soyez vigilant! Cette procedure prØsente des risques de danger! Ceux-ci sont identifis par des symboles adjacents aux directives. 4A A des _nd_fre 5/97 Identifie un message de sØcuritØ Ce groupe de symboles signifie Mise en garde! Soyez vigilant! lly a des risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN particulier. MOUVEMENTet aux PIECES CHAU DES. Reportez-vous aux symboles at aux directives ci-dessous at in de connaltre les mesures a ~ NOTA Signifie viter tout nest pas relatif a Ia sØcuritØ. prendre pour danger. Dangersrelatifs aU Soudage~:Fa!c~H.. A symboles prØsentØs ci-aprŁs sont utilisØs tout au long du present manuel pour attirer votre attention et identifier lea risques de danger. Lorsque vous voyez un symbole, soyez vigilantetsuivez lea directives mentionnØes afin dØviter tout danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne Ne pas toucherlØlectrode quandon est en contactavec Ia une electrode provenant dune autre machine. font que rØsumer linformation contenue dans lea normes de sØcuritØ ØnumØrØes ala section 1-5. Veuillez lire et respecter Porter Les toutes ces normes piŁce, Ia terre ou Nutiliser quun materiel en bon Øtat. RØparer ou remplacer sur-le-champ las piŁces endommagees. Entretenir lappareil conformØment A ce manuel. hamais de sØcuritØ quand un Maintenir solidement de sØcuritØ. en travaille on place tousles en hauteur. panneaux et capots. Fixerle cable de retourde facon a obtenir un bon contact mØtal-mØtal avec piŁce a souder ou a table de travail, le plus prŁs possible de Ia soudure. Isoler Ia pince de masse quand pas mis a Ia piŁce pour Øviter Ia contact avec tout objet metallique. Ia A lutilisation, Linstallatlon, doivent Œtre confiØs A Au cours qu lentretien et les reparations des personnes quallfiØes. de lutilisation, tenir toute personne Ł lØcart et les enfants ne plus . . particulierement LES RAYONS DE L.ARC peuvent pro voquer des brUlures dane lee yeux et~ sur Ia peau I I UN CHOC ~ ELECTRIQUE peut tuer ~_.. simple ______________ terre prØsentent No un danger. jamais toucher los piŁces electnques Porter des La rayonnement de larc ....... contact avec des piŁces Ølectnques peut provoquer une electrocution ou des blessuras 9raVes. LØlectrode et le circuit de soudage sont sous tension des que lappareil eat sur ON. La circuit dentrØe at les circuits intemes de lappareil sont egalement sous tension a ce moment-l. En soudage semi-automatique ou automatique, Jo fil, Ie dOvidoir, le logement des galets d entrainement at lea piŁces metalliques en contact avec le tilde soudaga sont sous tension. Des matØriels mal installØs ou mal mis ala Un gants et des sous sacs ne procØde de soudage genere infrarouges) peau. Des Øtincelles sont projetØes pendant Ia soudage. Porter un casque de soudage muni dun Øcran de filtre appropriØ pour pro teger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 at Z87.1 ØnumØre dans les Porter des trop ØlevØ. protections approuvŁs pour normes de sØcuritØ). las oreilles si le niveau sondre est Utiliserdas Øcrans ou des barriŁres pourprotegerdes tiers de lØclair at de lØblouissement; demander aux autres personnes de ne pas regarderlarc. tension. vOtemerits de protection du des rayons visibles at invisibles intenses (ultraviolets et susceptibles de provoquer des brOlures dans les yeux et sur Ia ________________ comportant pas de trous. Porterdes vŒtemonts de sistant feu au (lame ou protection constituØ dans une matiŁro durable, rØ at une protection des pieds. cuir) Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empŒcher le contact physique Øventuel avec Ia piŁce ou Ia terre. Ne passe servir de source Ølectrique humides, dans les endroits confines Se servir dune Acourant ou l o Olectrique Acourant le demande. source procØdØ de soudage electriqua dans on les zones risque de tomber. electrique UNIQUEMENT si Si lutilisation dune source electrique courant electnque savŁro nØces se servir de Ia fonction do tØlecommande si Iappareil en est equipe. Couper lalimentation ou arrŒter le moteur avant de proceder a linstallation, a Ia reparation ou a lentretien de lappareil. DØverrouiller lalimentation selon Ia norme OSHA 29 CFR 191 0.147 (voir normas de sØcuritØ). Installer et mettre a Ia terre correctement cat appareil conformØment A son manuel dutilisation at aux codes nationaux, provinciaux et municipaux. Toujours verifier Ia terre du cordon dalimentation Verifier et sassurerque le tilde terre du cordon dalimentation eat bien raccordØ ala borne de terre du sectionneur ou qua Ia fiche du cordon eat raccordØe a une pnse correctement mise A Ia terre. En effectuant lea raccordements dentrØe fixer dabord Ia conducteur do mise a Ia terre appropne et contra-verifier las connexions. frequemment le cordon dalimentation pour voir sil nest pas remplacer le cordon immØdiatement siI dommage ou dØnudŁ endommage un cable dØnudØ peut provoquer une electrocution. Verifier lappareil hors tension quand on Ne pas utiliser des cables uses, mal episses. no Le soudage genera des fumØes at des gaz. pout Œtre dangereux pour saire, Mettre I le en eat lutilise pas. endommages, de grosseur insuffisante ou Eloigner votra tŒte des fumØes. Ne pas respirer las fumØes. A Iinterieur, ventiler Ia zone atlou utiliser un echappement au niveau de arc pour lŁvacuation des fumØes at des gaz de soudaga. Si Ia ventilation est insuffisante, utiliser un respirateur a alimentation dair homologue. Lire Ies specifications de sØcuritØ des matØnaux (MSDS5) at las instruc tions du fabricant concemant las mØtaux, las consommables, les revOtemants, las nettoyants et les dOgraisseurs. Travaillardans SI Ia piŁce soudØe doit Œtre mise a Ia terre, le faire directement avec un cable distinct ne pas utiliser le connecteur da piŁce ou le cAble de retour. un espaca farmØ seulement siI est bion ventilØ ou en por. respirataura alimentation dair. Demandertouiours A un surveillant dOment formØ de se tenir A proximitØ. Des fumØes et des gaz de soudage peuvant deplacer lair at abaissar Ia nivaau doxygene provoquant des blessures ou des accidents mortals. Sassurer que lair de respiration ne presonte aucun danger. Na pas souder dans des androits situØs a proximitØ dopØrations do dØ graissago, de nattoyage ou do pulverisation. La chaleur at las rayons da Iarc peuvent reagir en presence do vapours at former des gaz hautement tant un toxiquas at irritants. No pas souderdes metaux munis dun rovŒtement, tels qua lacier galvani sØ, plaque en p10mb ou au cadmium a moms quo 10 revOtement nait ete de soudure, quo Iendroit soit bion vontilØ, ot si nØcos un raspirateur A alimentation dair. Les revOtements at renfermant tous los mØtaux cos ØlØments peuvent degagar des fumOes toxiques an cas de soudage. anlevØ dans Ia Ne pas enrouler lea cAbles autour du corps. Leur inhalation votre sante. saire, en zone portant OM-173 413 Page 5 LE.SOUDAGE pØt provoqiiæ. cendieou une.epiiion. In Le Prevoirunepertodede refroidissementavantdeffec des tuer des travaux dentretien. soudage effectue sur des conteneurs fermOs tels que reservoirs, tambours ou des conduites peut provoquer leur aclatement. Des atinceltes peuvent Otre projetees de larc de soudure. La projection dØtincelles, des piŁces chaudes et des Oquipementschauds peut provoquerdes incendies et des brOlures. Le contact accidental de electrode avec des objets metalliques peut provoquer des etincetles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, verifier et sassurer que tendroit ne presente pas de danger. Se esbrO lures~ provoqerd protager et dautres personnes de Ia projection detincelles Porter des gants et des vŁtements de sur un moteur chaud. protection pour travailler Ne pas toucher ~ mains recemment soudOes. nues es LE:BRurr et de metal parties chaudes du piŁces moteur ni les p~utaffecter.rqu~e.:, ~ chaud. Ne pas souderdans un endrolt i o substances intlammables. des etincelles peuvent tomber surdes Deplacer toutes es substances Intlammables a une distance de 10,7 larc de soudage. En cas dimpossibitite tes recouvrir soigneusement des protections homologues. m Le bruit des processus et des louie. Oquipements peut affecter de Porterdes avec protections approuvOs pour los oroilles si te niveau sondre est trop OlevO. Des etincelles et des materiaux chauds du soudage peuvent tacilement passer dans dautres zones en traversant de petites fissures et des ouvertures. Surveillertout declenchement dincendie et tenir un Le soudage effectue sur un plafond, plancher, paroi clencher un incendie de lautre cOtO. extincteur a ou I I proximitØ. LES CHAMPS MAGNETIQUES peuvent~ affecter lea stlmulateurscardlaques separation peut dO soudage surdes conteneurs ferrnOs tels que des reser voirs, tambours, conduites, a moms quits naient ete prepares correctement contormOment a AWS F4. 1 (voir les normes de securitO). Ne pas effectuer le ou 1=9 I - S .~ Les porteurs dun dabord consultor leur mØdecin avant de Ne pas utiliser le poste de En cas de non soudage pour degeler des conduites gelees. SI des BOUTEILLES sont -~ utilisation, enlever Ia baguette dOlectrode du porte-electrode . ou sapprocher des operations de soudage a larc, de gougeage de soudage par points. Brancher le cable sur Ia piŁce le plus pras possible de Ia zone de soudage pour eviter le transport du courant sur une longue distance par des che mins inconnus eventuels en provoquant des risques detectrocution et dincendie. - couper Ia fit a Ia pointe de contact. - ~ Porter des vOtements de protection dOpourvus dhuile tels que des gants en cuir, une chemise en matOriau lourd, des pantalons sans revers, des chaussures hautes et un couvre chet. ou endomma-] gØes, eHS1oUrrorftexpioSer....:...,J Des bouteifles de gaz protecteur contiennent du gaz sous haute presslon. Si une bouteilte est endommagØe, elle peut exploser. Du tait que es bouteiltes de gaz font ______________ Avant de souder, retirertoute substance combustible de quun atlumeur au butane ou des atlumettes. vos normatement partie du poches tetles avec arcs. Placer los bouteilles debout dans Le soudage, tOcaillement, to passage de Ia piŁce a Ia brosse en fit de for, et te meutage gOnOrent des Otincettes et des particutes mOtattiques votan tes. Pendant Ia pOriode de refroidissement des soudures, ettes risquent du taitier. Porter des lunettes de sOcurite avec manipuler Proteger las bouteilles de gaz comprimO dune chaleur excessive, des mecaniques, du taitler, des flammes ouvertes, des Øtincelles et des _____ projeter es chocs DES PAFITICULES VQLANTES. ~.:les yeur de procOde de soudage, precaution. ecrans tatOraux ou un ecran facial. un en las fixant dans un support stationnairo ou de se renverser. porte-bouteilles pour las ompOcher de tomber ou Tenir las bouteiltes OloignOes des circuits de soudage ou autres circuits electriques. Ne jamais placer Une electrode de teitle. Ne jamais une torche de soudage ne soudage dolt souder une bouteilte jamais sur une entrer pressurisOe boutoilto a gaz. en contact avec une bou risque dexploston. Utiliserseulement des bouteilles do gaz protecteur, regulateurs, tuyaux at raccords convenables pour cotta application specifique; las maintonirainsi que les elements assoclOs en bon Otat. Ne Farmer Ialimentation non du gaz protecteur en cas de Dangers F en cas dutitisation utilisation. Veiltertoujours a bien aOrertes espaces confines ou se servirdun respi rateur dadduction dair homologue. 14 pastenirta tetoenface data sortie en ouvrant Ia soupape data bouteille. Maintenirle chapeau de protection sur Ia soupape, sauf ou de branchement de Ia bouteilte. Lire at suivre es Instructions concemant los bouteilles do gaz comprtmO, los Oquipements associOs ot los publication P-i CGA OnumOrOes dans es normos de sOcurite. existent en relation avec Le moteur LA VAPEUR El LE LIQLHDE DE REFROIDISSEMENT CHAUD peUvent LE CARSURANT MOTEUR peut pro. voquer un incendte ou une explosion provoqy~des brOlures Ne pas faire le ArrOtorlo moteuravant do verifier Ia niveau decarbu rant ou do faire te plein. II No pas tairo 10 plein en fumant ou proche dune ce detincellos ou dune tiamme nue. rofroidissement de so brOter. sour plein do carburanta ras bord; prOvoirda Iaspace pourson expansion. Jotor los chiffons dans Page prOfOrabto Silo moteur est chaud at quo 10 une do verifier le liquide do fois Ia moteur ref roidi pour Ovifor tiquide doit etre vertfie, operer comme suivant: Faire attention do no pas renvorser do carburant. rant renversO avant do faire dOmarrer to moteur. OM-173 413 ost 6 un recipient ignifugo. Nottoyor tout carbu Mottro dos tunettos do sOcuritO ot dos gants, bouchon du radiateur. placer DOvissor to bouchon lOgŁremont of laissor Ia vapour dontever Ia bouchon. un torchon sOchapper sur 10 avant DES OR AMES MOBILES peuvent provoquer des blessures No pas approcher es mains des ventilateurs, roles et autros piŁces en mouvomont. Maintenir fermØs et fixement voquer des brlures dans lea YEUX et ~ iurIaPEAU.~ cour No pas renverser Ia batterie. I place los portes, panneaux, recouvrements et dispositifs de protection. ArrOter le moteur avant dinstallor ou brancher en Remplacer une batterie endommagee. Rincer immØdiatement lea yeux et Ia peau a leau. lappareil. Demander seulement a un personnel qualifie denlever les dispositifs de sØcuntØ ou lea recouvrements pour effectuer, all y a lieu, des travaux dentretien et de depannage. Pour empecher tout demarrage accidentel pendant es travaux dentre tien, dØbrancher le cable negatif () de batterie de Ia borne. Ne pas approcher lea mains, cheveux, vØtements lches et outils des ganes mobiles. or Utiliserlequipementa Remettre en place les panneaux ou lea dipositifs de protection et fermer lea portes a Ia fin des travaux dentretien et avant do faire dØmarrer le moteur. Avant dintervenir, dØposer les bougies en route accidentolle du moteur. Bloquer 10 volant moteur pour Øviter sur le ou sa injecteurs pour Oviter Ia mise lextOrieurdans des zones ou vertes et bien ventilØos. En cas dutilisatlon dans un ondroit fermØ Øvacuer les gaz dechappe mentdu moteurvors loxtØrieurŁ distance des entrØes dairdans lesbAti ments. rotation lors dune intervention gØnerateur. LEXPLOSION DE L~.ABArrERiEpeut LA CHALEUR DU MOTEUR peut incend j~i: ~ ~ voquŁrn - pro-i .:~. RENDREAVEUGLE Ne pas placer lappareil sur, au-dessus tØ de surfaces inflammables. protection faciale, des gants caoutchouc et vŒtements de protection lors dune Toujours porter tervention sur uno Eviter de provoquer des Øtincelles batteno. ou avec les outils en travaillant pourchargerles Observer Ia ) Debrancherle cable (+ correcte negatif () a distance los produits inflammablos do lØchappement. batteries ou sur NT! LE tTINCELLES ALEHAPPEME peuventpro~oqUei~UnncendIe~~..J Ia des ye EmpŁcher los Øtincelles dØchappement du et en a proximi do brancher lea cables de Ne pas utiliser le poste de soudage hicules de dØmarrage rapide. polaritØ Tenir in Ia battene. ArrOter le moteur avant de dØbrancher batteno. ou en sur do provoquer les batteries. un Utilisor uniquement un voir codes en viguour. premier lieu. Le rebrancheren demier lieu. moteur Incendlo. paro-etlncollos approuvØ 1-4. Dangers :pp1~mentair~en rØlatin avec Ibistallation, le to nctin:n !ment H ~ .:.....tI maintenance :::::H::: :: .. .. LA CHUTE DE LAPPAREIL LEMPLOJ peut . . . lanneau de levage uniquement pour soulever lapparoil lui-mOme sans chariot, do bouteilles do gaz, romorque, ou autros accessoires. Øquipement de levago pour lever lappareil. santo un do RØdulre le courant .. . . . ~ E11NCELLES VOLANTES risquent de provoquer des blessures ~ ~ Øcran facial pour proteger le . visage au . :.~::: tungstŁne uniquement a Ia mouleuse dotØe do du corps. risquent do causer un incendie Øloignertoute substance .~ Etablirlaconnexionaveclabarrettedeterreavantde manipulerdes cartos ou des ArrOter ou marrer ou dØconnecter lequipement darrŒter le moteur. pochettes pour stocker, dØplacer circuits imprimes. Ne pas brancherde moteurde 50 ou ou expØdier antistatiques des caries do :UNEREM QRQUE QUIBAUL::~ entratner di~ bIØsures~ supports de Ia remorque poids. des blocs ou pour soutenir 10 avant de dØ .:LES INSTRUCTIONS. frØquence trop faibles. de 60Hz ala ot des boites comme No pas laisser tourner 10 moteur trop lentement sous risque dendommager le motour electrique a cause tension et dune piŁces. ______________ Installer convenablement le poste sur Ia remorque indiquØ dans le manuel sy rapportant. mager le moteur electrique lieu. . piuvent ehd~mthagerIei::~cIrcuits~ imprimØs Utilisor los LESURCHAUFFEMENIPeut endrn. dune ... LES CHARGES ELECTRO STATIQUES Utiliser des protectours. Cette manoeuvre est a exØcuterdans un endroit sOr lorsque Ion Porte lequipement homologue do protection du visage, des mains et Los Øtincelles inflammable. 5, ~ et lea yeux. Affuterr lØloctrode le facteur do marcho avant do Ne pas obstruer los passages dair du poste. .. _________ un ou poursuivre le soudago. capacitØ suff I- oppose de lappareil. Porter :.; marche nominal. En utilisant des fourches do levage pour dØplacer lunitØ, sassurer quo les fourches sont suff isamment longues pour dØpasser du ctØ LES peut LaisserlØquipementrefroidir; respecterlefacteurde Utiliser Utiliser EXCESSIF ~suRcHAFER:LEouIpEMENT.~ ~ .: b~esŁer... . , prise do 100Hz, siI ya Utiliser MILLER. uniquement des piŁces do Effecteur Ia maintenance et Ia mise 10 manuel et colul du moteur. rechange en service daprOs OM-173 413 Page 7 I LE RAYONNEMENT HAUTE FRE~ Lenergie Le rayonnement haute frequence services de sØcuritØ et es les Veiller ace que tout des interferences, arrØter immØdialement le contrle Veillera souder a lappareil. ~j,.5,:..PrjflcjpaIØS. normes. dŁiØcuritØ Safety in Welding and Cutting, norme Welding Society, 550 N.W. Lejeune Rd, ANSI Z49.1, do lAmerican Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. RecommendedSafe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances, norme AWS F4.1, do IAmerican Welding Society, 550 N.W. Lojeune Rd, Mi ami FL 33126 National Electrical Code, NFPA Standard 70, do Ia National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. DonnØes des Information sur les distance de 100 metres de tout Veiller ment a ce ce quo ce poste de mode demploi. soudage solt pose et mis lo .;. .. ..~.:: Safe Handling of . Compressed Gases in cylinders, CGA Pamphlet P-i, do Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite 501, Arlington, VA 22202. de sOcuritd en soudage, coupage et procØdes connexes, CSA W117.2, de lAssociation canadienne de normalisation, vento do normes, 178 Rexdale Boulevard, Rexdalo (Ontario) Canada M9W 1R3. Regles norme Safe Practices For Occupation And Educational Eye And Face Protec tion, norme ANSI Z87.i, do lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51 B, de a National Protection Association, Batterymarch Park, Quincy, MA 02269. Afin de rØduire les do champs electromagnØtiques dans lonvironnement Gardor los cables ensembles en los torsadant attachant avoc du ruban adhØsif. 2 Mettre tous los cables du ctØ 3 No pas courber pas ot votre corps. node do recherche do 17 ans, un comitØ special ruban blou du de preuvos, sui National Research Council a conclu: Laccumulation 4 Garder le poste de do vous. pas dOmontrØ que Iexposition aux eloctriques a haute frØquence reprØ 5 comitØ, na Fire travail, respecter les consignes suivantes 1 soudage, pendant son passage dane los cables de sou dage, causora des champs electromagnØtiques. II y a eu et il y a encore un certain souci a propos do tels champs. Cependant, aprŁs avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pØ du Ia terre conformØ En cas dinterferences aprOs avoir pris les mesures precedentos, il incombo a lutllisateurde prendredes mesures supplØmentairestellesque le deplacementdu poste, lutilisation de cables blindØs, lutilisation de fil tres do ligne ou Ia pose de protecteurs dans Ia zone do travail. Lo courant do vant le equlpement Ølec champs e~ectromagnetiques soudage Ølectrique et sur los effets, pour iorganisme, champs magnetiques basso frØquence sur une tronique sensible. Øventuelles. ~1 -6 soudage soit compatible de linstallation. et lentretien regullerement MaintenirsoigneusementfermØs los portes et les panneauxdessources de haute frequence, maintenir los Oclateurs a une distance correcte et utilisor une terre et et un blindage pour rØduire les interferences Effectuer do provoquer Pour rØduire Ia possibilite dlnterfØrence, maintenir los cables do souda ge aussi courts que possible, los grouper, et los poser aussi bas que pos sible (ex. par terre). fiØ los interferences resultant de installation. signale do Ia zone de Iequipement OlectromagnOtiquement. ordinateurs. Demanderseulementdespersonnes qualif lees familiarisØes avecdes Øquipemonts Ølectroniques de faire fonctionner installation. Lutilisateurest tenu de faire corriger rapidement par un Olectncien quaIl Si Ia FCC electromagnetlque risque des Interferences pour lequipement Ølectronlque sensible tel que los ordinateurs et lØquipement corn mandØ par ordinateur tel quo es robots. (HF.) peut equipements provoquer des interferences avec les et de communication, de radionavigation d~i A L~ARC risque provo4Uer ~ .1 LE SOUDAGE QUENCE (H F) risque de provoquer des h~iterf6rencŁi.;~ jugement champs magnetiques et champs sento un risque a Ia sante humaino. Toutefois, des etudes sont toujours en cours et los preuves continuent a Œtre examinØes. En at Relier Ia pinco do ne los oppose de IopØrateur. pas ontourer pas los cables autour do soudage masse ou en le et les cables le plus plus prŁs possible loin do Ia possible zone do soudure. Consignes relatives aux stimulateurs cardiaques tendant quo los conclusions finales de Ia rechorcho soient Øtablies, il vous sorait souhaitable de rØduire votro exposition aux champs Ølec Los personnes qui portent un stimulateur cardiaque doivont avant tout consulter leur docteur. Si vous Œtes declare apte par votre docteur, il tromagnetiques pendant 10 soudage est alors recommandØ do OM-173 413 Page 8 ou 10 coupago. respecter les consignes cidossus. SECTION 2- DEFINITIONS 2-1. Warning Label Definitions Waming! Watch Out! There possible hazards symbols. as shown are by the Become trained and read the instructions before working on the machine or welding. 1 Electric shock from welding electrode or wiring can kill. 1.1 Weardry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1 .2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Do not work is 2 2.1 on unit if engine running. Stop engine first. Breathing welding fumes can be hazardous to your health. Keep your head of the out fumes. 2.2 Use forced ventilation exhaust to 2.3 Use ventilating fan to fumes. 3 3.1 Welding sparks explosion or fire. or local the fumes. remove remove cause can Keep flammables away from welding. Do weld not near flammables. 3.2 Welding sparks fires. Have fire a can cause extinguisher and have nearby, watchperson ready to use it. 3.3 Do not weld on drums closed containers. 4 or a any Arc rays can burn eyes and injure skin. 4.1 Wear hat and Use ear safety glasses. protection and button collar. shirt Use welding helmet with correct shade of filter. Wear complete body protection. 5 Do not (cover) 6 remove or paint Engine fuel plus flames sparks can cause fire. 6.1 Do not smoke while if near fuel. 6.2 or fueling or Stop engine before fueling. 6.3 Do not fuel 7 over the label. Engine a hot engine. exhaust gases can kill. 7.1 Vent exhaust outside. 7.2 Use unit outside. 3/96 OM-173 413 Page 9 1 Warning! Watch Out! There are possible hazards as shown by the symbols. 2 Do not matches smoke and and flames keep away from battery. 3 Sparks can explosion Wear 4 a Battery not spill battery Battery cause explode. to gases can blind and injure. face shield. acid can burn skin. Do acid. 5 Read Owners 6 Wear rubber 7 Dead 8 Engine 9 Fully charged battery 10 Do not connect last negative cable to dead battery connect instead to engine block. 11 Jumper Manual. gloves. battery block cables observe polarity and make connections numbered in sequence shown. 12 Once dead battery disconnect is charged, in cables sequence shown. 3196 Warning! Watch Out! There possible hazards as shown by the symbols. are 2 Moving parts, rotors, and such belts, as can fans, cut fingers and hands and cause injury. Keep away from moving parts. 2 3/96 OM-173 413 Page 10 1 2 Warning! Watch Out There are possible hazards as shown by the symbols. Hot muffler and exhaust can cause severe pipes burns. Do not touch hot muffler or pipes. 2~ S-176 230 3196 1 Warning! Watch Out! There are possible hazards as shown by the symbols. 2 Engine fuel plus flames sparks can cause fire. or Do not smoke while near fuel. or 3 fueling if 4 Stop engine before fueling. 5 Do not fuel 6 Use Diesel Fuel a hot engine. only. 3/96 1 2 Warning! Watch Out! There are possible hazards as shown by the symbols. Falling equipment can cause injury and damage. serious 3 lifting eye to lift or move Use only. proper equipment when lifting. Use unit 4 Do not use lifting eye to lift and support unit and trailer or other heavy devices or accessories. 3/96 OM-173 413 Page 11 Remove unit from S-177 571 shipping crate. Remove Owners Manual from unit. Follow instructions to install muffler. Read Owners Manual. Read on unit. labels Use Diesel Fuel fuel tank. Leave only, room and fill for expansion. Warningl Watch Outl There are possible hazards as shown by the symbols. Read Owners Manual. Follow instructions to activate battery. Check oil level. Add oil if necessary. During the first 50 hours of operation, keep welding load above 200 amperes. Do not weld below 200 amperes of output. After the first 50 hours of operation, change the oil and oil filter. 3/96 2-2. Manufacturers Rating Label For CE Products EN 60974-1 40AJ21V 325A/33V 504,/i 2V 400A/26V n = 1800 RPM 1P23 S-176 255-A OM-173 413 Page 12 2-3. Symbols And Definitions OM-173 413 Page 13 SECTION 3- SPECIFICATIONS Weld, Power, And Engine Specifications 3-1. Maximum Amperage Range Rated Welding Output OpenCircuit Voltage 250 A, 30 V DC, 100% Duty Cycle 60% Single-Phase, Deutz F3L-1 011 kVA/kW, 26/13 A, 120/240 V AC, Three-Cylinder, 60 Hz Engine 3 (Average) A, 33 V DC, Duty Cycle Engine Fuel Sound Capacity Power 11.3 US 100 Lwa IP Rating DC 96 40400 325 Auxiliary Rating Power Air/Oil-Cooled, gal (42.8 L) 29 HP Diesel 23 Dimensions, Weights, And Operating Angles 3-2. Dimensions 40-1/2 in Height A (625 mm) 24-5/8 in Width , (1029 mm) Do not exceed running (1422 mm) 56 in Depth A Do not could A 23-1/4 in (591 mm) B 24-5/8 in (625 mm) C 11/l6in(l7mm) D 2-7/8 in (73 mm) 4-1/2in(114)mm) E F 22-9/16 in G 27 in (573 mm) (686 mm) 30-3/8 in (772 mm) H Ref. ST-lb J 41 -1/4 in (1048 mm) K 51-1/8 in (1299 mm) L 54in 21/32 in M (1372 mm) (16.7 mm) Dia. 4 Holes 1/2 in N (12.7 mm) 10 Holes Weight 1500 lb OM-173 413 Page (680 kg) 14 Dia. 850-F or operating angles while engine damage will occur. move or tip. operate unit where It 3-3. Duty Cycle And Overheating 100% Duty Cycle At 250 Amperes Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. A Exceeding duty cycle damage unit and can void warranty. Continuous Welding 60% 6 Minutes Duty Cycle At 325 Amperes 4 Minutes Welding Resting 1000 800 600 (1) Ui 500 ci::: Ui 400 0~ 300 0 250 -J Ui 200 150 100 10 15 20 25 30 X DUTY 3-4. Volt-Ampere 40 50 60 80 100 CYCLE Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities 100 of the other welding generator. Curves of settings fall between the curves shown. 80 (n H 60 -J 0 > c~j 0 40 20 0 0 100 200 DC 300 400 500 AMPERES SB-183 882 OM-173 413 Page 15 AC 3-5. Auxiliary Power The ac power curve shows the in amperes avail 120 and 240 volt auxiliary power able at the receptacles. 300 150 ~ ::: :: C) < 75 150 50 100 25 50 0 0 5 0 AC 0 15 10 AMPERES IN 20 10 240V MODE 50 40 30 AC AMPERES 25 20 IN 120V MODE rsb3.1 2/92ST-log 3-6. Fuel 365-C Consumption The curve under weld shows or typical fuel power loads. use I -J 10 r-r~ = -J 7.57 1.67 2.00 6.81 1.50 1.80 6.06 1.33 1.60 5.30 1.17 1.40 4.54 1.00 1.20 - 3.79 0.83 1.00 - 3.03 0.67 0.80 - 2.27 0.50 0.60 - 1.51 0.33 0.40 0.76 0.17 0.20 0.00 0,00 0.00 0 50 I I I I I I I I 100 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100X DUTY CYCLE SB-137 487-A OM-173 413 Page 16 SECTION 4- INSTALLATION 4-1. Installing Welding Generator A Location Airflow Clearance Movement 18 in Do Not Lift Unit From End 15 in (460 mm) OR 18 in (4~m) (460 mm) Grounding 3 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Use #10 AWG Cable or larger insulated copper wire. OR A If unit does not have GFCI GFCI use receptacles, protected extension cord. Electrically bond generator frame to vehicle frame by metal-to-metal contact. 2 installl 3/96 Ref. ST-BOO 652 I Ref. ST-800 477-A / ST-i 58 936-A / S-0854 OM-173 413 Page 17 4-2. Activating The Dry Charge Battery Remove 1 battery from unit. Protection Safety Glasses Or Face Shield Eye Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well Fill each cell with bottom of well A electrolyte (maximum). Do not overfill battery to cells. Wait ten minutes and check elec trolyte level. If necessary, add elec trolyte to raise to proper level. Reinstall vent caps. 6 Battery Charger A 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 0 electrolyte is low, add only distilled water to cells to maintain proper level. 5 A For 30 Minutes 30 A For 12 Minutes Tools Needed: diybattl OM-173 413 Page 18 2/96 S-0886 4-3. Connecting 4-4. Engine The Battery Prestart Checks OM-173 413 Page 19 4-5. Installing Muffler Pipe A Stop engine A Do not blow exhaust toward air cleaner or air Intake. and let cool. 7~im~4~ \\ Tools Needed: ~ 1/2 in ST-8O1 376 1 Positive (+) Weld Output Terminal 2 Negative () Weld Output Terminal For Stick welding Direct Current (DCEP), con nect work cable to () terminal and electrode holder cable to (+) Electrode Positive terminal. For Direct Current Electrode ative (DCEN), reverse Neg cable connections. For FCAW cable to er () cable to welding, connect work terminal and wire feed () terminal. Tools Needed: -r 3/4in Ref. ST-801 344 OM-173 413 Page 20 4-7. Selecting Weld Cable Sizes Total Cable 100 ft Welding Amperes 10 (30 m) 60% Or Less 60100% (Copper) Length In Weld Circuit Not Exceeding 150ft I 200ft I 250ft I 300ft I 350ft I 400ft (45 m) I (60 m) I (70 m) I (90 m) I (105 m) I (120 m) I Duty 100% 10 I I I Duty Cycle Duty Cycle Cycle 100 4 4 4 3 2 1 1/0 1/0 150 3 3 2 1 1/0 2/0 3/0 3/0 200 3 2 1 1/0 2/0 3/0 4/0 4/0 250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0 4/0 2-2/0 2-3/0 2-3/0 300 1 1/0 2/0 3/0 350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0 400 1/0 2/0 3/0 4/0 2-210 2-3/0 2-4/0 2-4/0 500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0 Weld cable size (AWG) is based on either a 4 volts distributor for the mm2 equivalent weld cable sizes. or less drop or a current density of at least 300 circular mils per ampere. Contact your S-000l-E OM-173 413 Page 21 SECTION 5- OPERATING THE WELDING GENERATOR Front Panel Controls 5-1. Ref ST-176 748-C This unit has a max OCV control circuit that resets The AmperageNoltage Con trol to maximum when the arc breaks. is struck, weld output con trol returns to The front panel or remote control setting. The AmperageNoltage When an adjusts amperage only welding and does not adjust circuit voltage. when open- Switch 1 Ampere Range A Do not switch under load. AmperageNoltage output would be trols set OM-173 413 as (Optional) DC Ammeter (Optional) 5 Remote NV Switch And shown Control Page 22 se 140 A DC with con (50% of 90 to 190 (See 6 A). Section Magnetic gine Receptacle 5-3) Shutdown Switch To B (Optional) Engine Control Switch To Start: turn switch to Start while pressing Shutdown switch. Release switches when engine starts. Do not crank engine if engine is still runs at idle speed at no load and weld speed with load applied. Use switch during start-up to bypass option al engine shutdown system. System stops engine if oil pressure is too low oroil temper ature is too high. 7 Control adjusts amperage within range lected by Ampere Range switch. Weld DC Voltmeter 4 arc Control 2 3 tuming. position, engine runs at weld/power speed. In Run/Idle position (optional), en- Stop: turn switch to Off Light goes 9 position. Battery Charging Waming Light on when Oil Pressure battery is not charging. Warning Light Light goes on if oil pressure is too low. Light also goes on if oil temperature is too high (if unit has automatic shutdown option). A Stop engine and light goes on. 10 Engine 11 Oil Temperature fix trouble if either Hour Meter Gauge/Switch (Optional) In Run 12 Oil Pressure Gauge/Switch (Optional) 5-2. Manual Shutoff Lever Manual Shutoff Lever 1 Use lever to stop engine if engine control switch does not work. Ref. ST-801 344 5-3. Remote NV Control r1~ Use switch to select front panel remote amperage control. Remote Amperage Remote A/V 2 1~Q~ Example: Combination A/V Control Switch 1 A/V 2 Connect RC3. Control optional or Receptacle RC3 remote control to In Example: Range =90 to 190 A Percentage Of Range 50% Max 140 A DC (50% of 90 to 190) = 120-240 90-190 = 50 0 10 90 Max(14OADC)F 1 I~I Min(66ADC) I A/V Set Switch Set Range Set Percentage Adjust Optional Remote Control S-0774 OM-173 413 Page 23 SECTION 6- OPERATING AUXILIARY EQUIPMENT 6-1. 120 Volt And 240 Volt Duplex Receptacles A If unit does not have GFCI receptacles, use GFCI-pro tected extension cord. ~ If a circuit breaker continues to open, contact Factory Autho rized Se,vice Agent. U~ Auxiliary power is not affected by weld output. 1 240 V 15 A AC RC1 Receptacle 2 120 V 15 A AC Receptacle RC2 Receptacles supply 60 Hz singlephase power at weld/power speed. 3 Circuit Breakers CB1 And CB2 CB1 protects RC1 and CB2 pro tects RC2 from overload. If CB1 or CB2 opens, the receptacle does not work. present 120 volts may still be at RC2. output from each duplex receptacle is 1.8 kVA/kW, and 3 kVA/kW from all receptacles. Maximum 2 EXAMPLE: If 10 A is drawn from RC1, only 5 A is available at RC2: (240 V x 10 A) + (120 V x 5 A) = 3.0 kVA/kW 3 Ref. ST-176 748-C OM-173 413 Page 24 6-2. Optional Auxiliary 4~ 17 Power Receptacles A If unit does not have GFCI receptacles, *KD use GFCI-pro tected extension cord. ~ If circuit breaker continues to open, contact Factosy Autho rized Service Agent. ~ Auxiia,y power is by weld output. GFCI not affected Receptacle Option 120 V 15 A AC GFCI 1 Recep tacle GFCI1 Auxiliary power output and circuit breaker protection is the same as standard receptacles (see Section 6-1). If a ground fault is detected, GFCI Reset button pops out and recep tacle does not work. Check for tools plugged in Press button to reset. faulty ~ At least gine at once a receptacle. month, run en weld/power speed and press test button to verify GFCI is working properly. 2 240 V 13 A AC British tacle RC1 3 240 V 16 A AC South African Receptacle RC1 4 240 V 10 A AC Australian Receptacle RC1 5 Circuit Breaker CB1 Recep Receptacle supplies 60 Hz singlephase power at weld/power speed. Maximum output is 3 kVA/kW. CB1 protects the receptacle from overload. If CB1 opens, the recep tacle does not work. 120 volts may still be present at the 240 V recep tacle. Combined output of all is 3 kVA/kW. receptacles Ref. ST-176 748-C/ Ref. ST-169 671-A OM-173 413 Page 25 SECTION 7- MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance A Recycle engine fluids. Stop engine before maintaining. See also Engine Manual and Mainte Service engine more often during severe conditions. nance Label. / lOOh fi 200h Change Oil. See Section 7-4. l000h 3000 h OM-173 413 Page 26 0) D) CD 0 CD I a. CD 751-B in) in) 5-176 (0.012 (0.020 F) (72 13m (1/2in.) 0.3 0.5 20 266 067 std. mm mm C 17-956 ex. in. MIL ER Deutz h 500 77. F86 68 59 50 41 32 23 14 5. 4. 265 067 217 066 13 22 31 40 ,~ 2.MILER ,~ 16-426 MIL ER Deutz ~ ~~I~iI~1 I~- CDISF std std. CD/SE, h h API 250 750 17-469 Deutz 1064 7 852 4A P352 MIL ER Nelson Fram bet er) (or 5.9L(62qt) 1 std.I h 10 0 anualy. chekd P10-275 be should std. Injectors h 50 (0F) AMIL ER 297C Donaldson CAK AC 70206 Fram Nelson 20td.~ DF-2 it DIESL (1 .3 2-D 1-D, DF-1, L ' 45 256 gal) -18C I~I 880 126 42.8 A 12V BCI 520 601 51 RPM 120 RPM 1850 8hstd. ~DIN BS2869:A1, 975-81: DF-A, D 80 C: ASTM V -F ff II S<=.5% ~.. 0 I C.) C.) -u 0) Co 0) r) -J 7-3. Servicing Air Cleaner A Stop engine. 1 Intake Manifold 2 Service Indicator 3 Window 4 Reset Button (Optional) Service air cleaner element if red band appears in window. A green band means air cleaner is okay. Press button to reset indicator. 2 A 3 Do not run air cleaner element. without with dirty engine or Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings. Cap 5 Dust 6 Baffle 7 Element 8 Plastic Fins 9 Housing To Clean air filter: 9 87 6 5 Wipe off cap and housing. Remove cap and dump out dust. Wipe dust from inside cap and housing with damp cloth. Remove element and reinstall cap. A Do not clean air hose. housing with Clean element with compressed air only. Keep nozzle at least 1 in (25 mm) from inside of element. Max. air pressure: 100 psi (690 kPa). Do not remove plastic fins. Replace element if it has holes or damaged gaskets. Reinstall element and cap (dust ejector down). Blow Inspect aircleaner2 6/96 OM-173 413 Page 28 ST-153 929-B / Rel. ST176 748-C / ST-153 585 / Ref. S-0698-B 7-4. Oil And Fuel System Components ~ii1 and let cool. A Stop engine 1 Oil Filter 2 Oil Drain Valve 3 Oil Fill 4 Primary Fuel Filter (Fuel/ Water Separator) 5 Petcock 6 Secondary 7 Fuel Shutoff Valve 8 Fuel Line change oil See Fuel Filter Drain Sludge 9 To Cap Plug and filter: manual. engine A Close oil drain valve and cap, and place In holder be fore adding oil and running engine. To drain water from fuel system: fuel filter petcock and drain water into metal contain er. Close petcock when water-free fuel flows. Open primary To replace primary fuel filter: Close shutoff valve and turn filter counterclockwise. Remove filter. coat of fuel to gasket on filter, Install new filter and turn clockwise. Open shutoff valve. Bleed air from fuel system accord ing to engine manual. Apply thin new 3 6 Inspect fuel line, and replace cracked To it or worn. replace secondary fuel filter: See engine To drain manual. sludge from fuel tank: Put metal container under drain, and remove sludge drain plug. Re install plug when done. A After servicing, start engine and check for fuel leaks. A Stop engine, tighten nections con necessary, and wipe up spilled fuel. as Close doors. LI Tools Needed: ~ 7/l6in LI I I I Ref. ST-i 76 748-C / ST-801 334-A / Ref. 5-176 697 / Ref. S-0842 OM-173 413 Page 29 7-5. Adjusting Engine Speed After tuning engine, check engine no load speed with a tachometer (see table for no load speeds). If adjust necessary, follows: Start Turn speed as engine and run until warm. AmperageNoltage Control to 100. Standard Models: Engine Speed Adjustment 1 Screw 2 Locking Nut Loosen nut. Turn gine runs Models at until en 1850rpm. Tighten nut. With screw Automatic Idle (Optional) 3 Throttle Rod 4 Locknut locknuts. Place engine control switch in Run/Idle position. Loosen Turn throttle rod until engine runs at idle speed. Tighten locknuts. 5 Engine Speed Adjustment Screw 6 Locknut Place engine position. control switch in Run Loosen locknut. Turn screw until engine runs at weld/power speed. Tighten locknut. A Stop engine. Tools Needed: ~ 3/8,7/16 in Ref. ST-801 344-A OM-173 413 Page 30 7-6. Overload Protection A Stop engine. ~ If any fuse continues to open, contact Facto,y Authorized Se,vice Agent. 1 Magnetic Shutdown Switch MS1 2 Fuse F (See Parts List For Rating) Fuse F protects magnetic shut down switch MS1. 3 Throttle Solenoid Fuse F4 F4 protects the throttle solenoid from overload on models with auto matic idle option. Check fuses and replace if open. Tools Needed: Ref. ST-801 344 / Ref. ST-156 199-B I ST-801 320-A 7-7. Optional Spark Arrestor Inspection And Cleaning A Stop engine 1 Spark 2 Cleanout and let cool. Arrestor Plug Remove plug covering cleanout hole. 3 Exhaust and remove any dirt Pipe Start engine and run at idle speed to blow outcleanout hole. If nothing blows out of hole, briefly cover end of exhaust pipe with fireproof material. A Stop engine and let cool. Reinstall cleanout plug. Tools Needed: ~ 3/8in ST-800 523 I Ref. ST-176 748-c OM-173 413 Page 31 Troubleshooting 7-8. ~tid~a~i~ A. Welding Remedy Trouble Check No weld output. position of Ampere Range switch. Place AN control switch in Panel position, or place switch in Remote position and connect remote perage control to Remote NV receptacle (see Section 5-3). Check and Have secure Factory Use output. Be Authorized Service equipment from Disconnect Erratic weld dry, properly sure connections to Remote NV ac Agent am receptacle. slip rings, check brushes and receptacles RCI and RC2 and field excitation circuit. during start-up. stored electrode. connection to work piece is clean and tight. Remove excessive coils from weld cables. Check and Have Low or high weld both inside and outside unit. Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit. Adjust engine speed (see Section 7-5). output. Have open-circuit voltage. Low tighten connections Factory Authorized Service Agent check field Check Have engine speed, and Factory Authorized adjust if necessary Service current regulator board PCi. (see Section 7-5). Agent check integrated rectifier SR2, AmperageNoltage control Ri, and resistor R2. Maximum weld output only in each ampere range. B. Auxiliary Have Factory Authorized Service Agent check AmperageNoltage control R1,capacitor C8, integrated rectifier SR4, and control relay CR2. Power Remedy Trouble No output receptacles. auxiliary at power Reset circuit breaker CB1 and/or CB2 Disconnect Have Low or high output receptacles. OM-173 413 diode D8, Page at 32 auxiliary power equipment Factory from ac (see Section receptacles RC1 Authorized Service Agent Adjust engine speed (see Section 7-5). 6-1 or and RC2 6-2). during start-up. check brushes and slip rings, and field excitation circuit. Troubleshooting 7-8. ~I~d~$$~ A. Welding Remedy Trouble No weld position of Ampere Range switch. Check output. Place NV control switch in Panel position, or place switch in Remote perage control to Remote A/V receptacle (see Section 5-3). Check and Have secure Factory Disconnect Use Erratic weld output. Be connections to Remote A/V Authorized Service equipment from ac Agent connect remote am receptacle. check brushes and receptacles position and RC1 and RC2 slip rings, and field excitation circuit. during start-up. dry, properly stored electrode. sure connection to work piece is clean and tight. Remove excessive coils from weld cables. Check and Have Low or Factory both inside and outside unit. Authorized Service Agent check brushes and slip rings, and field excitation circuit. Adjust engine speed (see Section 7-5). high weld output. Have open-circuit voltage. Low tighten connections Check Have Service Factory Authorized engine speed, and Factory Authorized Agent check field current regulator board PCi. adjust if necessary (see Section 7-5). Service Agent check integrated rectifier SR2, AmperageNoltage control Ri, and resistor R2. output only Maximum weld in each ampere range. B. Auxiliary Factory Authorized Service Agent check AmperageNoltage control integrated rectifier SR4, and control relay CR2. Have output receptacles. Remedy auxiliary at power Reset circuit breaker CB1 and/or CB2 Disconnect Have Low or high output receptacles. OM-173 413 capacitor C8, diode 08, Power Trouble No Ri Page 32 at auxiliary power equipment from ac (see Section receptacles Factory Authorized Service Agent Adjust engine speed (see Section 7-5). 6-1 or RC1 and RC2 6-2). during start-up. check brushes and slip rings, and field excitation circuit. C. Engine Remedy Trouble Engine Check fuel level. does not start. Check optional Open fuel valve (see Section 4-4). shutdown switch fuse F and replace if open (see Section 7-6). Check battery and replace if necessary. Check connections to Engine Control switch. Check oil level. Optional automatic shutdown system stops engine if oil pressure gets too low or oil tem perature gets too high. See engine Have manual. Factory Authorized Service Agent check engine charging system. Check optional magnetic shutdown switch fuse F and replace if open (see Section 7-6). Engine suddenly stops. Check oil level. perature gets Engine slowly stopped; unable engine. to re- Optional high. automatic shutdown system stops engine if oil pressure gets too low or oil tem too Check fuel level. Open fuel valve (see Section 4-4). start Engine does not stop when Engine Control switch is placed in Off position. Use manual shutoff leverto stop engine (see Section 5-2). Check connections to Have Factory Authorized Service Agent check engine fuel solenoid. Engine remains at idle speed when Engine Control switch is placed in Run/ Idle position and an arc is struck. (Mod els with automatic idle option only.) Have Engine will not run at idle speed. (Models with automatic idle option only.) Check throttle solenoid fuse F4, and Battery discharges between uses. Factory Authorized Service Agent check replace Engine Control switch if open Factory Authorized Service Agent check Engine Control switch Make sure Clean battery, terminals, and posts in Off with position when baking soda and Periodically recharge battery (approximately every and idle module. (see Section 7-6). Have Engine Control switch is Engine Control switch. three and idle module. unit is shut down. water solution; rinse with clear water. months). Replace battery. Engine uses oil during wetstacking occurs. run-in period; Dry engine (see Section 9). See engine manual OM-173 413 Page 33 SECTION 8- ELECTRICAL DIAGRAM ~ dol :: : AW. - ~pRr L~II~J SC-182 851-A Figure OM-173 413 Page 34 8-1. Circuit Diagram For Welding Generator SECTION 9- RUN-IN PROCEDURE run_in 1 6/96 9-1. Wetstacking ____________________________ Welding Generator 1 Run diesel engines rated near output during run-in period to prop erly seat piston rings and prevent wetstacking. See nameplate or rating label to find rated output. ~ 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 dur ing run-in. 2 Engine Exhaust Weistacking Pipe 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 ing engine using one of run-in procedures. the follow See the tional engine manual for addi engine run-in information. OM-173 413 Page 35 9-2. Run-In Procedure Using Load Bank A Stop engine. A Do not touch hot exhaust pipe, engine parts, or load bank/grid. A Keep exhaust and from flammables. 1 Load Bank pipe away Turn all load bank switches Off. If needed, connect load bank to 115 volts tor 2 ac wall receptacle or genera auxiliary power receptacle. Welding Generator Place AN range switch in maxi mum position, AN control in mini position, and Output Selector (if present) in either DC position. mum switch 3 Weld Cables Connect load bank to generator weld output terminals using proper size weld cables with correct Observe connectors. correct polarity. Start engine and minutes. run for several Set load bank switches and then adjust generator A/V control so load equals rated generator output (see nameplate). Check generator and load bank meters after first five minutes then every fifteen minutes to be generator is loaded properly. UT Check oil/eve! 3- ing run-in; sure frequently dur add oil if needed. After one hour (minimum) place A/V control in minimum position, then turn off load bank to remove load. Run engine several minutes at no load. A Stop engine 4 Engine and let cool. Exhaust Pipe Repeat procedure if wetstacking is present. S-0683 OM-173 413 Page 36 9-3. Run-In Procedure Using Resistance Grid A Stop engine. A Do not touch hot exhaust or load pipe, engine parts, bank/grid. A Keep exhaust and from flammables. 1 Resistance Grid Use grid sized for pipe away generator rated output. Turn Off 2 grid. Welding Generator Place A/V range switch in maxi position, A/V control in mini mum position, and Output Selector switch (if present) in either DC mum position. 3 Weld Cables Connect grid to generator weld output terminals using proper size weld cables with correct connec (polarity is not important). tors 4 Voltmeter 5 Clamp-On Ammeter Connect voltmeter and ammeter as shown, if not provided on generator. Start engine and minutes. Set .5 grid run for several switches and then adjust generator A/V control so load equals rated generator output (see nameplate). Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly. ~ Check oil level frequently dur ing run-in; add oil if needed. After one hour (minimum), place A/V control in minimum position, then shut down grid to remove load. Run engine several minutes at no load. A Stop engine 6 and let cool. Engine Exhaust Pipe Repeat procedure present. if weistacking is S-0684 OM-173 413 Page 37 SECTION 10 Hardware is common PARTS LIST and not available unless listed. 7 9 10 11 12 96 22 95 23 / 67 68 69 70 72 71 75 76 Figure OM-173 413 Page 38 10-1. Main Assembly 11 34 29- 43 27. 26 44 Figure 10-2 61 59 57 53 62 ST-801 345-D OM-173 413 Page 39 Item No. Dia. Part No. Mkgs. Description Figure 1 . 175657 175724 Neg 039 046 Pos 039 047 601 879 601 880 2 175013 175012 3 +173322 173321 004130 173346 176751 176108 +173313 4 176105 176104 5 035968 6 173324 10-1. Main Quantity Assembly TERMINAL, output bracket BRACKET, brace terminal weld output TERMINAL, pwr output black (consisting of) TERMINAL, pwr output red (consisting of) 1 NUT, stl hex full fnsh .500-13 NUT, stl hex jam .500-13 PANEL, side LH PANEL, side RH DOOR, side LH DOOR, side RH BRACKET, support door LATCH, paddle LABEL, diesel engine maintenance LABEL, warning battery explosion 1 COVER, top LABEL, general precautionary LABEL, warning falling equipment WASHER, flat 3.625 ID x 5.875 OD 1 1 1 2 2 1 1 1 1 2 x .O62thk 9 020185 124973 11 125467 12 125704 13 089517 14 175488 15 170615 16 168670 BASE 173326 PAN, base 108081 107972 8 115000 605 288 124941 19 089914 BOLT, 20 124668 HOLD DOWN, 010460 STUD, stl .312-18 CABLE, bat neg 032453 ...23 111352 Figure 24 10-2 25 124406 26 173304 27 173307 ...28 109591 29 176745 30 176744 124984 1 1 1 1 1 1 1 1 1 2 1 1 1 18 22 1 1 TERMINAL PROTECTOR, CABLE, bat pos 17 1 1 10 7 1 1 SKIRT, base LH SKIRT, base RH TANK, fuel 11 gal (consisting of) CAP, fuel FITTING, pipe galv plug sq hd .25ONPT FITTING, pipe brs elb st 1/8NPT FITTING, hose brs barbed M 1/8tbg x 1/8NPT HOSE, nprn SAE .125 ID x .343 OD x 7.000 FITTING, hose brs splice 1/8tbg x 1/8tbg STRAP, fuel tank ROD, fuel shutoff UPRIGHT, base center 173325 1 L stl .312-18 BATTERY, x battery post 9.000 battery x 2 1 1 1 10.000 1 1 stor 12V 3BOcrk GENERATOR 1 1 BRACKET, mtg engine COVER, air baffle bottom COVER, air baffle top CLAMP, muffler 1.7SOdia PIPE, exhaust PIPE, muffler extension elbow BRACKET, mtg air cleaner LH 1 1 1 2 1 1 1 32 ,046545 RESTRICTION INDICATOR 1 33 ,010089 FITTING, brs coupling 1/8 AIR CLEANER, intake CLAMP, hose 1 .125-3.000clp dia HOSE, aircleaner CLAMP, hose 1.312-3.2SOclp dia BAFFLE, air sides & bottom BAFFLE, air BOX, air exhaust GUARD, beltLH LABEL, warning moving parts 1 34 124986 35 010863 36 124985 37 023313 38 173303 39 173315 40 173306 ..41 +175 078 176106 OM-173 413 Page 40 1 3 1 2 1 1 1 1 2 Item No. Dia. Part No. Mkgs. Description Figure 173319 BOX, air intake engine 1 DIFFUSOR ASSEMBLY 1 173302 HOSE, CWC flexaust 2.500 ID x 6.000 Ig CLAMP, hose 1 .875-3.75Oclp dia PANEL, rear GUARD, belt RH GUARD, blower CLAMP, modified ENGINE, Deutz 173310 44 +175077 45 173320 173301 173903 47 .127648 48 +127994 +175936 .126388 .124946 .010 021 .072 082 +118679 52 .125663 53 .175937 54 TS1 .... .124974 55 124402 ...56 071890 58 071730 072848 59 173929 60 176528 113 854 023 562 165 271 176 529 173 336 175 076 179 661 145 282 172 071 010 323 ..70 084210 ..71 106467 ...72 175431 73.... CR99 74... Idle mod 75 ...76 ... .. +090 104 .142 724 +176775 F4 +073429 77 +046432 ...78 178 507 026 947 iT 038 621 038 620 081 499 010 146 181 122 ...82 83... SR1,2,4 035 704 D8 034 502 170 673 ...86 ...88.... Assembly (Continued) 067274 605 409 50 10-1. Main Quantity 1 1 1 1 1 1 1 CLEVIS, throttle BALL JOINT, .250-28 ROD, throttle NUT, .250-28 LH BRACKET, arm throttle CLAMP, sti cush .562dia x .343mtg hole BUSHING, stl .265 ID x .499 OD x .593 Ig SCREW,M6-1.0x30 BALL JOINT, .250-28 LH BRACKET, support solenoid SOLENOID, 12VDC BRACKET, mtg engine RH RETAINER, mount eng/gen TUBING, stl .875 OD x l2ga wall x 2.500 TUBING, nprn .875 ID x 2.500 OD x 2.000 BRACKET, mtg solenoid FITTING, hose brs barbed elb fem 1/2tbg x 1/2NPT HOSE, SAE .500 ID x .780 OD (order by ft) CLAMP, hose .312-.875cIp dia VALVE, oil drain 3/8-18NPTF FITTING, hose brs barbed fem 1/2tbg x 3/8NPT FITTING, adapter oil drain GUARD, stator BASE, filter w/adapter and vent FITTING, hose brs barbed elb M 5/l6tbg x 1/4NPT CLAMP, hose .520-.605c1p dia CLAMP, hose .250-.625c1p dia HOSE, SAE .312 ID x .560 OD x 19.000 FILTER, fuel spin-on BRACKET, mtg separator fuel RELAY, end 12VDC SPST MODULE, pull to idle 5 pin BRACKET, mtg comp panel auto idle FUSE, mintr gI slo-blo 1 5A 32V HOLDER, fuse mintr .250 x 1.250 panel mtg INSULATION, terminal strip STAND-OFF, insul .250-20 x 1.000 Ig BLOCK, term 30A 4P LINK, jumper term blk BRACKET, mtg strip terminal CLAMP, nyl .625c1p dia PANEL, mtg components 1 1 1 1 1 1 2 2 1 1 1 1 1 4 4 1 1 2ff 2 1 1 1 1 1 2 3 1 2 1 1 1 1 1 1 1 1 1 1 2 1 I 1 RECTIFIER, integ 40A 800V DIODE, zener 12V 50W KIT, diode mounting DIODE, board 3 1 1 Dl 128 299 08 170 674 R6 CR2 030 844 CAPACITOR BOARD RESISTOR, WW fxd 25W 25 ohm 059 267 RELAY,encI12VDCDPDT 1 1 1 1 OM-173 413 Page 41 Dia. Item No. Part No. Mkgs. Description Figure 173317 89 Figure 90 10-3 129074 CT1 92 .... ,105370 111310 108163 ...95.... 128862 R2,3 96 085656 97 110069 98 175432 99 097829 116045 165669 168071 +When ordering *Recommended 10-1. Main Assembly (Continued) PANEL, front lower PANEL, front w/components 1 REACTOR 1 TRANSFORMER, current UPRIGHT, base front FRAME, mtg reactor & fuel tank RESISTOR, WW adj 375W 50 ohm STRIP, mtg resistor FITTING, flrd brs elb 1/4tbg x 1/4NPT VALVE, shutoff fuel BOLT, J stl .250-20 x 2.750 1 1 1 1 2 1 2 1 4 CONNECTOR & SOCKETS CONNECTOR&SOCKETS CONNECTOR & SOCKETS component originally displaying Spare Parts. a Quantity a precautionary label, 1 1 1 the label should also be ordered. OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. Hardware is common and not available unless listed. 20 21 ST-lw 922-E Figure OM-173 413 Page 42 10-2. Generator Item No. Dia. Part Mkgs. No. Description Figure 10-2. Generator (Figure Quantity 10-1 Item 24) 106426... INSULATOR 106 440... BUS BAR, rectifier 1 2 SR3 4 2 106 427... DIODE 1 4 048 420 ASSEMBLY, reverse polarity (consisting of) CAPACITOR, rectifier 2 106 641 CAPACITOR 1 5 037 957 DIODE, 3 6 106425 7 173 066... 8 018 614... 3 *151 299 9 10 600 270 11 152 044 12 176 106... 13 124 855... 14 +174 002... 15 039 207 16 089 736... 17 024 617 18 053 390 19 089 737 035 776 INSULATOR 2 BRACKET, mtg brushholder BRUSH SET, (consisting of) BRUSH,contact HOLDER, brush CAP, brushholder LABEL, warning moving parts GUARD, stator STATOR, gen (consisting of) BAFFLE, air gen ROTOR, gen (consisting of) RING, retaining external BEARING, ball FAN, rotor KEY, .375 x .375 1 3 1 1 1 can cause serious injury 2 1 1 1 1 1 1 1 x 2.000 1 STATOR, excitor 173 068... ENDBELL, gen (consisting of) 143220 0-RING, 2.859 IDx.139CS 173 323... BARREL, rectifier 106 430... DIODE ASSEMBLY, (consisting of) 048 420 CAPACITOR, rectifier 20 044 374... 21 22 23 24 rect 275A 300V RP ... SR3 25 26 106 425 CAPACITOR INSULATOR 27 037 956 DIODE, 046 819 SUPPRESSOR 106 641 28. VR1,R4 ... *Recommended Spare +When a ordering 1 1 1 1 1 2 1 1 rect 275A 300V SP 3 1 Parts. component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-173 413 Page 43 fl~ Hardware is common and not available unless listed. 1 Figure 10-4 4 21~$ 5 6 7 8 18 9 10 11 15 14 13 12 ST.801 358-B Figure OM-173 413 Page 44 10-3. Panel, Front w/Components Dia. Item No. Mkgs. Part No. Description Figure 1 604103 RECEPTACLE,strdxgrd2P3Wl5A25OV 1 025 234 PLUG, str grd 2P3W 15A 250V RECEPTACLE, str dx grd 2P3W 1 5A 1 25V PLUG, str grd 2P3W 15A 125V Arrow Hart 5965V CIRCUIT BREAKER, man reset 1 P 1 5A 25OVAC KNOB, pointer PLATE, ident control rating (order by model and serial number) BOOT, toggle switch lever GAUGE, pressure oil 15-20 GAUGE/SWITCH, temp oil 250 deg KIT, oil line 44.000 in i/8NPT x 10mm FITTING, pipe brs adapter 1/8NPT x 12 mm LEVER, switch black HOLDER, light md BULB, incand fig base 12V LENS, light md red METER, hour 4-4OVDC HANDLE, switch range NAMEPLATE, (order by model and serial number) SWITCH, ignition Sposn PANEL, front upper 175 412 011 072 . . *048 317 011 609 .. 5 032 897 .. 7 .... RC2 170 901 073 690 8 .... CB1 ,2 139266 148 723 9 10 11 021 385 12 .129 860 13 .129 837 .128 829 .128 633 119 014 14 082 788 15 16.... PL1,2 18 *048 155 082 789 17 HM 145 247 019 754 19 20 21 Si 22 . .. 4 .... 90) 1 .. RC1 10-1 Item SWITCH, automatic shutdown (consisting of) SWITCH, magnetic (consisting of) FUSE, mintr gI 14A 32V SWITCH, tgl SPDT 15A 125VAC RECEPTACLE, twlk grd 2P3W 15A 125V .. 605960 6 w/Components (Figure 1 114 193 Ri F Front RHEOSTAT, WW 300W 34 ohm S3 MS1 Panel, SWITCH, range (Figure 10-4) 1 2 3 10-3. Quantity 172 070 127 618 . 1 - 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 i OPTIONAL *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-173 413 Page 45 Item No. Part No. 114 235 BRACKET, mtg switch (consisting of) SPRING, ext x .312 OD x .042 wire x 1.875p1d LOCATOR, quadrant CONTACT BOARD ASSEMBLY, switch range (consisting of) CONTACT BOARD, movable switc CONTACT ASSEMBLY, movable (consisting of) SPRING, pressure 004 998 011 980 011 645 011 075 011 953 011 074 011 644 . Switch, Range (Figure 10-3 Item 1) Figure 017 428 11 004 999 12. 011 012 100 623 10-4. Quantity 114 193 010 671 . Description 1 1 1 1 2 3 1 CONTACT 2 SPRING, pressure CONTACT, stationary CONTACT BOARD, stationary SHIM, guide contact board GUIDE, contact board movable 1 15 2 3 3 ~ Hardware is common and not available unless listed. 3 4 ST-oil 273 Figure 10-4. Switch, Range To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-173 413 Page 46 Part No. Quantity Description OPTIONAL EQUIPMENT 043 096 042 318 .. RECEPTACLE KIT, 120V GFCI ENGINE PROTECTION PACKAGE, (consisting of) AUTOMATIC SHUTDOWN, low oil pres & hi temp .... 043088 .... 041 671 .... 1 1 (Fig 10-1, 10-3) 1 AUTOMATIC IDLE, (Fig 10-1, 10-3) SERVICE INDICATOR KIT, (Fig 10-1) 1 1 OM-173 413 Page 47 Notes __ ___ ___
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