OM-481
132 366T
July 2002
Processes
Stick (SMAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Submerged Arc (SAW) Welding
Stud Welding
Air Carbon Arc (CAC-A) Cutting
and Gouging
Description
Engine Driven Welding Generator
R
Big Blue 600D
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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. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
3
4
4
5
5
5
6
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
1-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. AC Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
9
9
9
WARNING
Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.
9
10
10
11
11
12
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Exhaust Pipe And Rain Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Selecting Weld Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Remote 14 Receptacle RC3 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Terminal Strip 3T Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
14
15
15
16
17
CALIFORNIA
Proposition 65
Warning
SECTION 5 – OPERATING THE WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Example Of Remote Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-1. 120 Volt Duplex GFCI Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. 240 Volt Duplex Receptacle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
18
19
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
19
20
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Adjusting Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Checking And Replacing Engine Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-8. Servicing Optional Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9. Adjusting Overspeed Shutdown Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
22
23
24
25
25
26
26
27
28
The following terms are
used interchangeably
throughout this manual:
Stick = SMAW
MIG = GMAW
SECTION 8 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 9 – RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
33
34
SECTION 10 – AUXILIARY POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SECTION 11 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
rom _nd_4/02
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
.
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1-2. Arc Welding Hazards
Y
The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D
D
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.
Y
Y
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
SIGNIFICANT DC VOLTAGE exists in inverters after
stopping engine.
ELECTRIC SHOCK can kill.
D
Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
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
ARC RAYS can burn eyes and skin.
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.
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
groundedequipment is a hazard.
D
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D
D
D
Do not touch live electrical parts.
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.
D
D
D
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Wear protective clothing made from durable, flame-resistant mate-
rial (wool and leather) and foot protection.
D
D
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
FUMES AND GASES can be hazardous.
D
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).
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D
D
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
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.
D
D
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D
D
When making input connections, attach proper grounding conduc-
tor first – double-check connections.
D
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.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D
D
D
D
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.
D
D
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.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
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 if necessary, while wearing an
air-suppliedrespirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
D
D
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.
OM-481 Page 1
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WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
D
D
Allow cooling period before maintaining.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Wear protective gloves and clothing when
working on a hot engine.
D
Do not touch hot engine parts or just-welded
parts bare-handed.
NOISE can damage hearing.
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
damagehearing.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D
Wear approved ear protection if noise level is
high.
D
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D
D
Watch for fire, and keep a fire extinguisher nearby.
MAGNETIC FIELDS can affect pacemakers.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D
D
Pacemaker wearers keep away.
D
D
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).
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
CYLINDERS can explode if damaged.
D
D
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D
D
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D
D
Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, 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.
FLYING METAL can injure eyes.
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
D
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
D
Wear approved safety glasses with side
shields even under your welding helmet.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D
D
Turn face away from valve outlet when opening cylinder valve.
BUILDUP OF GAS can injure or kill.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
D
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Engine Hazards
STEAM AND HOT COOLANT can burn.
FUEL can cause fire or explosion.
D
D
If possible, check coolant level when engine is
cold to avoid scalding.
D
D
Stop engine and let it cool off before checking or
adding fuel.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
Do not add fuel while smoking or if unit is near
any sparks or open flames.
D
If the engine is warm, checking is needed, and
there is no overflow tank, follow the next two
statements.
D
D
D
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.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before completely
removing cap.
OM-481 Page 2
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BATTERY ACID can BURN SKIN and
EYES.
MOVING PARTS can cause injury.
D
D
Keep away from fans, belts, and rotors.
D
D
D
Do not tip battery.
Keep all doors, panels, covers, and guards
closed and securely in place.
Replace damaged battery.
Flush eyes and skin immediately with water.
D
D
Stop engine before installing or connecting unit.
Have only qualified people remove guards or covers for maint-
enance and troubleshooting as necessary.
D
D
D
D
D
To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
ENGINE EXHAUST GASES can kill.
Keep hands, hair, loose clothing, and tools away from moving
parts.
D
D
Use equipment outside in open, well-ventilated
areas.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
If used in a closed area, vent engine exhaust
outside and away from any building air intakes.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
ENGINE HEAT can cause fire.
D
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
BATTERY EXPLOSION can BLIND.
Keep exhaust and exhaust pipes way from
flammables.
D
D
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.
EXHAUST SPARKS can cause fire.
D
D
D
D
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.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas – see applicable codes.
Disconnect negative (–) cable first and connect it last.
1-4. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
D
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, trailer, or any other
accessories.
Reduce current or reduce duty cycle before
starting to weld again.
D
Use equipment of adequate capacity to lift and
support unit.
D
Do not block or filter airflow to unit.
D
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.
D
D
Put on grounded wrist strap BEFORE handling
boards or parts.
FLYING SPARKS can cause injury.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
D
D
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.
TILTING OF TRAILER can cause injury.
D
Sparks can cause fires — keep flammables away.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
OVERHEATING can damage motors.
D
Turn off or unplug equipment before starting or
stopping engine.
READ INSTRUCTIONS.
D
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
D
D
Use only genuine MILLER replacement parts.
Perform engine maintenance and service
according to this manual and the engine
manual.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
OM-481 Page 3
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H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
D
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
D
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D
Have only qualified persons familiar with
electronic equipment perform this installation.
D
Be sure all equipment in the welding area is
electromagneticallycompatible.
D
D
The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D
D
D
D
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.
D
D
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.
1-5. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
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.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting 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
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.
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
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.
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 possi-
ble.
About Pacemakers:
To reduce magnetic fields in the workplace, use the following
procedures:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-481 Page 4
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
rom _nd_fre 4/02
1-1. Signification des symboles
SignifieMise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
Y
Identifie un message de sécurité particulier.
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
.
S
i
g
n
i
f
i
e
N
O
T
A
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
1-2. Dangers relatifs au soudage à l’arc
D
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ
les pièces endommagées. Entretenir l’appareil conformément à ce
manuel.
Y
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 sécu-
rité énumérées à la section 1-5. Veuillez lire et respecter toutes
ces normes de sécurité.
D
D
D
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
D
avec tout objet métallique.
Y
Y
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée
comme indiqué dans la Section Maintenance avant de toucher des compo-
sants.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets et
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension dès
que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
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.
D
Porter un casque de soudage muni d’un écran de filtre approprié pour pro-
téger votre visage et vos yeux pendant le soudage ou pour regarder (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D
D
Ne jamais toucher les pièces électriques sous tension.
D
D
D
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Porter des gants et des vêtements de protection secs ne comportant pas
de trous.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de
l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, ré-
sistant au feu (laine ou cuir) et une protection des pieds.
D
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-
lants suffisamment grands pour empêcher le contact physique éventuel
avec la pièce ou la terre.
D
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
Si l’utilisation d’une source électrique àcourant électrique s’avère néces-
saire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation,
à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation
selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
D
D
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
D
D
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air
homologué.
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.
Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-
tions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-
tant 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.
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de
mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-
dommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations de dé-
graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz hautement
toxiques et irritants.
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-
sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été
enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-
saire, en portant un respirateur à alimentation d’air. Les revêtements et
tous les métaux renfermant ces éléments peuvent dégager des fumées
toxiques en cas de soudage.
D
D
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.
D
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
OM-481 Page 5
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LE SOUDAGE peut provoquer un in-
cendie ou une explosion.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
Prévoir une période de refroidissement avant d’effec-
tuer des travaux d’entretien.
Le soudage effectué sur des conteneurs fermés tels que
des réservoirs, tambours ou des conduites peut provoquer
leur éclatement. Des étincelles peuvent être projetées de
D
Porter des gants et des vêtements de protection pour
l’arc de soudure. La projection d’étincelles, des pièces chaudes et des
équipements chauds peut provoquer des incendies et des brûlures. Le contact
accidentel de l’électrode avec des objets métalliques peut provoquer des
étincelles, une explosion, un surchauffement ou un incendie. Avant de
commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.
travailler sur un moteur chaud.
D
Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces
récemment soudées.
LE BRUIT peut affecter l’ouïe.
D
D
D
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec
des protections homologués.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
D
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-
clencher un incendie de l’autre côté.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
D
D
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
Brancher le câble sur la pièce le plus près possible de la zone de soudage
pour éviter le transport du courant sur une longue distance par des che-
mins inconnus éventuels en provoquant des risques d’électrocution et
d’incendie.
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normale-
ment partie du procédé de soudage, les manipuler avec
précaution.
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électro-
de ou couper le fil à la pointe de contact.
D
D
Porter des vêtements de protection dépourvus d’huile tels que des gants
en cuir, une chemise en matériau lourd, des pantalons sans revers, des
chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des
chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des
arcs.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
D
Placer les bouteilles debout en les fixant dans un support stationnaire ou
dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.
D
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques vo-
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits
électriques.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
lantes. Pendant la période de refroidissement des soudures, elles ris-
quent de projeter du laitier.
Une électrode de soudage ne doit jamais entrer en contact avec une bou-
teille.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
D
D
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.
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation
ou de branchement de la bouteille.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
D
Lire et suivre les instructions concernant les bouteilles de gaz comprimé,
les équipements associés et les publication P-1 CGA énumérées dans les
normes de sécurité.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut pro-
voquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
D
D
Arrêter le moteur avant de vérifier le niveau de carbu-
rant ou de faire le plein.
D
Il est préférable de vérifier le liquide de
refroidissement une fois le moteur refroidi pour éviter
de se brûler.
Ne pas faire le plein en fumant ou proche d’une sour-
ce d’étincelles ou d’une flamme nue.
D
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
D
Toujours vérifier le niveau de liquide de refroidissement dans le vase
d’expansion (si présent), et non dans le radiateur (sauf si précisé autre-
ment dans la section maintenance du manuel du moteur).
Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-
rant renversé avant de faire démarrer le moteur.
D
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme
suivant :
Jeter les chiffons dans un récipient ignifuge.
Mettre des lunettes de sécurité et des gants, placer un torchon sur le
bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant
d’enlever le bouchon.
OM-481 Page 6
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DES ORGANES MOBILES peuvent
provoquer des blessures.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Ne pas approcher les mains des ventilateurs, cour-
roies et autres pièces en mouvement.
D
D
D
Ne pas renverser la batterie.
D
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
D
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
Demander seulement à un personnel qualifié d’enlever les dispositifs de
sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux
d’entretien et de dépannage.
LES GAZ D’ÈCHAPPEMENT DU
MOTEUR peuvent provoquer des
accidents mortels.
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entre-
tien, débrancher le câble négatif (–) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-
ganes mobiles.
D
Utiliser l’équipement à l’extérieur dans des zones ou-
Remettre en place les panneaux ou les dipositifs de protection et fermer
les portes à la fin des travaux d’entretien et avant de faire démarrer le
moteur.
vertes et bien ventilées.
D
En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-
ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti-
ments.
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise
en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention
sur le générateur.
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
D
Ne pas placer l’appareil sur, au-dessus ou à proximité
de surfaces inflammables.
D
Toujours porter une protection faciale, des gants en
caoutchouc et vêtements de protection lors d’une in-
tervention sur la batterie.
D
Tenir
à
distance les produits inflammables de
l’échappement.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de
batterie.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la
batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-
hicules de démarrage rapide.
D
D
Empêcher les étincelles d’échappement du moteur
de provoquer un incendie.
D
D
Observer la polarité correcte (+ et –) sur les batteries.
Utiliser uniquement un pare-étincelles approuvé –
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier
lieu.
voir codes en vigueur.
1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
LA CHUTE DE L’APPAREIL peut
blesser.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Utiliser l’anneau de levage uniquement pour soulever
l’appareil lui-même ; sans chariot, de bouteilles de
gaz, remorque, ou autres accessoires.
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Utiliser un équipement de levage de capacité suffi-
sante pour lever l’appareil.
Ne pas obstruer les passages d’air du poste.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
D
Porter un écran facial pour protéger le visage et les
yeux.
D
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
D
D
Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-
tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque
l’on porte l’équipement homologué de protection du visage, des mains et
du corps.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
Les étincelles risquent de causer un incendie – éloigner toute substance
inflammable.
D
D
Utiliser les supports de la remorque ou des blocs
pour soutenir le poids.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
Installer convenablement le poste sur la remorque
comme indiqué dans le manuel s’y rapportant.
D
Arrêter ou déconnecter l’équipement avant de dé-
marrer ou d’arrêter le moteur.
LIRE LES INSTRUCTIONS.
D
Ne pas laisser tourner le moteur trop lentement sous
risque d’endommager le moteur électrique à cause
d’une tension et d’une fréquence trop faibles.
D
D
Utiliser seulement les pièces de rechange d’origine.
Effecteur la maintenance et la mise en service
D
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
d’après le manuel et celui du moteur.
lieu.
OM-481 Page 7
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LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement com-
mandé par ordinateur tel que les robots.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements
de radio–navigation et de communication, les
services de sécurité et les ordinateurs.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
D
D
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
sible (ex. par terre).
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
fié les interférences résultant de l’installation.
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
D
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
ment à ce mode d’emploi.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et et un blindage pour réduire les interférences
éventuelles.
En cas d’interférences après avoir pris les mesures précédentes, il in-
combe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
tres de ligne ou la pose de protecteurs dans la zone de travail.
1-5. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Weld-
ing Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
RecommendedSafe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
Safe Practices For Occupation And Educational Eye And Face Protec-
tion, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
NationalElectrical Code, NFPA Standard 70, de la National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-6. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
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 ex-
aminé plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Re-
search 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 con-
clusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
2
3
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4
5
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
OM-481 Page 8
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SECTION 2 – DEFINITIONS
2-1. Symbols And Definitions
Fast (Run, Weld/
Power)
Stop Engine
Start Engine
Battery
Engine
Check engine belt
Oil Pressure
Hourmeter (HM)
Do Not Switch
Under Load
Read Operator’s
Certified/Trained
Mechanic
Engine Oil
Manual
Check Injectors/
Pump
Check Valve
Clearance
Engine Oil Temper-
ature
Fuel
Positive
Negative
Volts
Wire Feed
Welding Arc
Amperes
On
Panel/Local
Remote
Output
A
V
Direct Current
(DC)
Alternating
Current
Stick (SMAW)
Welding
Air Carbon Arc
Cutting (CAC-A)
MIG (GMAW)
Welding
Protective Earth
(Ground)
Electrode
Connection
Circuit Breaker
Time
Temperature
Hours
Work Connection
Seconds
h
s
SECTION 3 – SPECIFICATIONS
3-1. Weld, Power, And Engine Specifications
Maximum
Weld
Welding
Mode
Rated Welding
Output
Open-Circuit
Voltage
Generator Power
Rating
Output
Range
Engine
Fuel Capacity
(Nominal)
Deutz F4L-912
Air-Cooled,
Four-Cylinder,
61 HP Diesel
Engine
CC/DC
CV/DC
45 – 800 A
Single-Phase,
3 kVA/kW, 26 A,
120 V AC, 60 Hz
600 A, 44 Volts DC,
100% Duty Cycle
95 (80)
15 gal (57 L)
14 – 44 V
OM-481 Page 9
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3-2. Dimensions, Weights, And Operating Angles
Dimensions
Height
58 (1473 mm)
32 (813 mm)
C
A
B
Width
Y
Y
Do not exceed operating angles
while running or engine damage will
occur.
Depth
68 in (1727 mm)
1-1/16 in (27 mm)
29-7/8 in (759 mm)
6-1/8 in (156 mm)
9-3/4 in (248 mm)
13-3/4 in (349 mm)
28-3/16 in (716 mm)
36 in (914 mm)
D
E
F
A
B
C
D
E
F
Do not move or operate unit where it
could tip.
G
H
J
K
G
H
J
17.5°
46-1/2 in (1181 mm)
50-1/2 in (1283 mm)
62-3/8 in (1584 mm)
15°
20°
20°
Engine End
K
L
21/32 in (17 mm) Dia.
16 Holes
L
Weight
ST-153 650
angles_1 3/96
2250 lb (1021 kg)
3-3. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
ST-133 838-A
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3-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
100% Duty Cycle At 600 Amperes
Y
Exceeding duty cycle can
damage unit and void
warranty.
ContinuousWelding
1000
800
600
500
400
300
250
200
150
100
10
15
20
25
30
40
50
60
80
100
% DUTY CYCLE
sb1.1 8/93 SB-134 397-C
3-5. AC Generator Power
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
rsb3.1 2/92 – ST-109 365-C
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3-6. 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. For Constant Current (CC) Mode
B. For Constant Voltage (CV) Mode
SB-133 004-A / SB-133 003-A
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SECTION 4 – INSTALLATION
4-1. Installing Welding Generator
Movement
Airflow Clearance
Location
18 in
(460 mm)
Y
Do Not Lift Unit From End
18 in
(460 mm)
18 in
(460 mm)
OR
OR
18 in
(460 mm)
18 in
(460 mm)
Grounding
Y
Always securely fasten
welding generator onto
transport vehicle or trailer
and comply with all DOT and
other applicable codes.
1
2
GND/PE
Y
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricityhazards.
If unit does not have GFCI re-
ceptacles,
use
GFCI-
protected extension cord.
Electrically bond generator frame to
vehicle frame by metal-to-metal
contact.
1
2
3
Equipment Grounding
Terminal (On Front Panel)
3
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
install1 7/02 – Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854
4-2. Connecting The Battery
Y
Connect Negative (–)
Cable Last.
+
OFF
–
RUN
START
Tools Needed:
1/2 in
ST-153 654-B / Ref. SD-131 784-A / Ref. S-0756-B
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4-3. Installing Exhaust Pipe And Rain Cap
Y
1
Stop engine, and let cool.
Exhaust Pipe
3
2
Muffler Pipe
Install exhaust pipe over muffler
pipe. Secure exhaust pipe to top
cover using supplied hardware.
OFF
1
3
Rain Cap
RUN
Install so cap opens toward front of
unit.
2
Y
Do not blow exhaust toward
air cleaner or air intake.
START
Tools Needed:
1/2 in
Ref. ST-156 467-C
4-4. Engine Prestart Checks
Check all fluids daily. Engine must
be cold and on a level surface.
. This unit has a low oil pressure
shutdown switch. However,
some conditions may cause
engine damage before the en-
gine shuts down. Check oil lev-
el often and do not use the oil
pressure shutdown system to
monitor oil level.
Full
Follow run-in procedure in engine
manual.If unburned fuel and oil col-
lect in exhaust pipe during run-in,
see Section 9.
Fuel
Y
Do not use gasoline. Gaso-
line will damage engine.
Add fresh diesel fuel before starting
engine the first time (see mainte-
nance label for specifications). Fill
fuel tank up to 1/2 in. (13 mm) from
top to allow room for expansion.
Do not run out of fuel or air enters
fuel system and causes starting
problems. See engine manual to
bleed air from fuel system.
Oil
After fueling, check oil with unit on
level surface. If oil is not up to full
mark on dipstick, add oil (see main-
tenance label).
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
starting:
Keep battery in good condition.
Store battery in warm area off
concrete surface.
1/2 in
(13 mm)
Full
Use fuel formulated for cold
weather (diesel fuel can gel in
cold weather). Contact local
fuel supplier for fuel in-
formation.
Tools Needed:
3/8 in
Diesel
Use correct grade oil for cold
weather.
ST-156 467
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4-5. Connecting To Weld Output Terminals
1
2
Positive (+) Weld Output Terminals
Tools Needed:
3/8, 7/8 in
Negative (–) Weld Output Terminals
For Direct Current Electrode Positive
(DCEP), connect work cable to Negative
(–) terminal and electrode holder cable to
Positive (+) terminal.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
1
2
To prevent overheating and damage, two
terminals are provided for each polarity in
case more than one cable is needed to
carry current to a single arc (see Section
4-6). This unit is not designed to supply
multiplearcs.
Ref. ST-134 687-B / ST-174 733
4-6. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
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)
Weld Output
Terminals
Y
Y
Turn off power before
connectingto weld out-
put terminals.
10 – 60% 60 – 100%
Welding
Amperes
Duty
Duty
10 – 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
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
400
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
2/0 (70)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(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)
1/0 (60)
4/0 (120)
4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0
(2x70) (2x95) (2x120) (2x120)
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)
500
600
700
800
900
1000
2/0 (70)
3/0 (95)
3/0 (95)
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)
4/0 (120)
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)
4/0 (120)
4/0 (120)
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)
(3x120)
(4x120)
(4x120)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
2 ea. 2/0
(2x70)
2 ea. 3/0
(2x95)
2 ea. 4/0
(2x120)
3 ea. 3/0
(3x95)
* Chart is a guideline and may not suit all applications. If cable overheating occurs (normally you can smell it), use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm for metric use
2
S-0007-E–
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
OM-481 Page 15
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4-7. Remote 14 Receptacle RC3 Information
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB4.
A
J
K
I
B
C
L
B
Contact closure to A completes 24
volts ac contactor control circuit.
N
H
M
D
G
F
E
I
115 volts ac. Protected by circuit
breaker CB3.
J
Contact closure to I completes 115
volts ac contactor control circuit.
G
C
Circuit common for 24 and 115
volts ac circuits.
OR
0 to +10 volts dc output to remote
control from min to max of Amper-
age/Voltage control R1.
D
E
Remote control circuit common.
A/V
0 to +10 volts dc input command
signal from remote control.
Ref. ST-800 907-A
K
Chassis common.
*The remaining sockets are not used.
OM-481 Page 16
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4-8. Terminal Strip 3T Connections
Y
Stop engine.
OFF
If remote control plug does not fit in
receptacle RC3, wire cord directly
to terminal strip 3T.
RUN
Y
Do not connect to Remote 14
receptacleRC3 and terminal
strip 3T at the same time. Use
only one remote control
method.
START
1
Open right side door.
1
2
Terminal Strip 3T
Strain Relief
Ω
REMOTE
Connect leads to 3T using terminal
information shown in Section 4-7.
CONNECTIONS
A
Secure cord in strain relief.
Reinstall cover. Close door.
B
24 VAC
C
2
1 K
D
E
NEUTRAL
G
115 VAC
I
EQUIPMENT
GROUND
K
J
S-138 042-A
Tools Needed:
Ref. ST-131 784-A / Ref. ST-121 578-D / Ref. S-184 781
OM-481 Page 17
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SECTION 5 – OPERATING THE WELDING GENERATOR
5-1. Front Panel Controls
3
1
2
4
5
6
7
8
9
10
11
12
ST-134 687-B
15
14
13
1
Voltmeter
Ammeter
(see Sections 4-7 and 4-8).
tion, engine stops automatically when speed
exceeds normal rpm.
7
CC/CV Selector Switch
2
11 Engine Hour Meter
12 Fuel Gauge
Use switch to select type of weld output. Use
CC for Stick (SMAW) welding and Air Carbon
Arc Cutting. Use CV for wire feed processes
(MIG, FCAW, SAW). If using CV, place Am-
pere Range switch in maximum position.
3
Ampere Range Switch
Y
Do not switch under load.
13 Battery Ampere Gauge
Use switch to select weld amperage range.
For most welding applications, use lowest
amperagerange possible to help prevent arc
outages.
Use gauge to check amperage output to the
battery. The gauge reads near 0 (zero) when
the engine is running. If gauge is at a negative
number, the battery is discharging.
8
Output (Contactor) Switch
Use switch to control remote contactor con-
nected to receptacle RC3 or terminal strip 3T
(see Sections 4-7 and 4-8).
4
Amperage/Voltage Control
Y
Stop engine, and do not run until prob-
lem is fixed.
Control adjusts amperage within range se-
lected by Ampere Range switch. Example:
weld output would be 90 A DC with Ampere
Range switch in 55 to 125 A DC/CC position
and Amperage/Voltage control set at 50 (50%
of 55 to 125 A).
9
Check Cooling System/Alternator Light
14 Oil Pressure Gauge/Switch
Y
Stop engine and check engine belt if
light goes on (see Section 7-7).
Use gauge/switch to check oil pressure. Nor-
mal operating pressure is about 50 psi (345
kPa). Engine stops if oil pressure is too low.
10 Engine Control Switch
Use switch to start engine and stop engine.
5
Service Engine Air Cleaner Light
Y
Do not run engine until problem is
fixed.
In Run position, engine runs at weld/power
speed all the time.
Service engine air cleaner if light goes on (see
Section 7-3).
15 Oil Temperature Gauge/Switch
To Start: turn Engine Control switch to Start.
Release switch when engine starts.
6
Amperage/Voltage Control Switch
Use gauge/switch to check oil temperature.
Use switch to select front panel or remote am-
perage control (see Section 5-2).
Normal operating temperature is about 225°F
. If the engine does not start, let engine
come to a complete stop before attempt-
ing restart.
(107° C). Engine stops if oil temperature is too
For front panel control, place switch in Panel
position. For remote control, place switch in
high.
Remote position and connect remote control To Stop: turn Engine Control switch to Off
to Remote 14 receptacle or terminal strip 3T position. If unit has overspeed shutdown op-
Y
Do not run engine until problem is
fixed.
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5-2. Example Of Remote Amperage Control
In Example:
Min = 55 A DC/CC
Percentage Of Range = 50%
Max = 90 A DC/CC (50% of 55 to 125)
Set Switches
Set Range
Set Percentage
3
Min (55 A DC/CC)
2
Max (90 A DC/CC)
Adjust Remote Control
S-0774 / S-0769
SECTION 6 – OPERATING AUXILIARY EQUIPMENT
6-1. 120 Volt Duplex GFCI Receptacles
3
1
2
4
Ref. ST-174 733
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
CB1 protects GFCI1 and CB2 protects
GFCI2 from overload. If CB1 or CB2 opens,
the receptacle does not work.
. At least once a month, run engine at
weld/power speed and press Test but-
ton to verify GFCI is working properly.
. If a circuit breaker continues to open,
contact a Factory Authorized Service
Agent.
4
Total Generator Power Output
1
2
120 V 20 A AC GFCI
Receptacle GFCI1
Maximum output from each duplex recep-
tacle is 1.8 kVA/kW, and 3 kVA/kW from all
receptacles. Generator power is not af-
fected by weld output.
120 V 20 A AC GFCI
Receptacle GFCI2
If a ground fault is detected, the GFCI Reset
button pops out and the circuit opens to dis-
connect the faulty equipment. Check for
damaged tools, cords, plugs, etc. con-
nected to the receptacle. Press button to re-
set receptacle and resume operation.
Receptacles supply 60 Hz single-phase
power at weld/power speed.
EXAMPLE: If 15 A is drawn from GFCI1,
only 10 A is available at GFCI2:
3
Circuit Breakers CB1 And CB2
(120 V x 15 A) + (120 V x 10 A) = 3.0 kVA/kW
OM-481 Page 19
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6-2. 240 Volt Duplex Receptacle (Optional)
1
3
2
Ref. ST-174 733 / ST-174 757
Y
If unit does not have GFCI recep-
tacles, use GFCI-protected exten-
sion cord.
2
3
120 V 20 A AC Duplex Receptacle
GFCI2 (Section 6-1)
4
. If a circuit breaker continues to open,
contact a Factory Authorized Service
Agent.
Circuit Breakers CB1 And CB2
4
Total Generator Power Output
1
240 V 15 A AC Duplex
Receptacle RC1
Combined output of all receptacles limited
to 3 kVA/kW output of the generator.
CB1 and CB2 protect the 120 V and 240 V
receptacles from overload. If CB1 or CB2
opens, the 240 V receptacle and one half of
the 120 V receptacle does not work. 120
volts may still be present at the 240 volt re-
ceptacle. Press button to reset breaker.
EXAMPLE: If 10 A is drawn from the 240 V
receptacle, only 5 A is available at the 120
V receptacle:
Receptacle supplies 60 Hz single-phase
power at weld/power speed. Maximum out-
put from this receptacle is 3 kVA/kW.
(240 V x 10 A) + (120 V x 5 A) = 3.0 kVA/kW
SECTION 7 – MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an
extended period.
Note
Y
Stop engine before maintaining.
.
S
e
e
a
l
s
o
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
-
Recycle engine
fluids.
nance Label. Service engine more often
if used in severe conditions.
*
To be done by Factory Authorized
Service Agent.
8 h
FUEL
WATER
Check Fluid
Levels. See
Section 4-4.
Drain Water
From Fuel
System.
Wipe
Up
Spills.
OIL
Full
50 h
Clean And
Tighten
Weld
Clean Air Filter.
See Section 7-3.
Terminals.
OM-481 Page 20
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100 h
Change Oil
Filter. See
Section 7-4.
Change Oil. See
Section 7-4.
Clean And
Tighten
Battery
Check
air
cleaner hoses
for cracks and
loose clamps.
Connections.
200 h
250 h
Replace
Unreadable
Labels.
Check And
Clean Spark
Arrestor. See
Section 7-8.
500 h
Repair Or
Replace
Cracked
Cables.
1000 h
Service Welding
Generator Brushes
And Slip Rings.
Service More Often
In Dirty Conditions.*
Blow Out Or
Drain Sludge
From Fuel
Tank. See
FUEL
SLUDGE
Vacuum Inside.
During Heavy
Service,
OR
Section 7-4.
Clean Monthly.
Check
Valve
Clearance.*
Check Belt
Tension. See
Section 7-7.
1/2 in.
(13 mm)
Change Fuel
Filters. See
Section 7-4.
3000 h
Clean/Set
Injectors.*
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7-2. Maintenance Label
OM-481 Page 22
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7-3. Servicing Air Cleaner
Y
Y
Stop engine.
Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
1
3
4
2
OFF
.
T
h
e
a
i
r
c
l
e
a
n
e
r
p
r
i
m
a
r
y
e
l
e
m
e
n
t
c
a
n
RUN
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.
START
Optional
5
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.
Keep nozzle
2 in (51 mm)
from element.
1
2
3
4
5
Housing
Safety Element (Optional)
Primary Element
Dust Cap
Dust Ejector
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.
Blow
Inspect
Y
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.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 2/01 – ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-481 Page 23
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7-4. Servicing Fuel And Lubrication Systems
Y
1
Stop engine and let cool.
Oil Filter
2
Oil Drain Plug
OFF
3
Secondary Fuel Filter
4
Primary Fuel Filter/Water
Separator
RUN
5
6
Petcock
Sludge Drain Plug
START
To change oil and filter:
See engine manual.
To drain water from fuel system:
Open petcock and drain water into
metal container. Close petcock
when water-free fuel flows.
To replace primary fuel filter/ wa-
ter separator:
Turn filter counterclockwise. Re-
move filter.
Apply thin coat of fuel to gasket on
new filter. Install new filter and turn
clockwise. Bleed air from fuel sys-
tem according to engine manual.
3
Inspect fuel line, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:
2
Put metal container under drain,
and remove sludge drain plug. Re-
install plug when done.
1
Y
After servicing, start engine
and check for fuel leaks.
Y
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
6
Close doors.
4
5
Tools Needed:
7/16 in
Ref. ST-153 653-A / Ref. SD-131 784
OM-481 Page 24
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7-5. Adjusting Engine Speed
Y
Stop engine.
Engine speeds have been factory
set and should not require adjust-
ment. After tuning engine, check
engine speeds with a tachometer.
See table for proper no load
speeds. If necessary, adjust
speeds as follows:
Engine Speed
RPM
Weld/Power
1850
1
2
Speed Adjustment Screw
Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/powerspeed. Tighten locknut.
2
Y
Stop engine.
1
Close side door.
Tools Needed:
9/16, 7/8 in
Ref. ST-134 730-C / Ref. SD-131 784-A
7-6. Overload Protection
Y
Stop engine.
OFF
. When a fuse or circuit breaker
opens, it usually indicates a
more serious problem exists.
Contact a Factory Authorized
Service Agent.
RUN
1
Circuit Breaker CB3
START
CB3 protects the 115 volts ac out-
put to Remote 14 receptacle RC3 or
terminal strip 3T. If CB3 opens, the
115 volts ac output stops.
2
Circuit Breaker CB4
CB4 protects the 24 volts ac output
to Remote 14 receptacle RC3 or
terminal strip 3T. If CB4 opens, the
24 volts ac stops.
1
2
Press button to reset breaker.
3
4
Fuse F (See Parts List)
Fuse F6 (See Parts List)
4
Remove screw to open upper front
panel access door.
Fuse F protects the magnetic shut-
down switch MS1 from damage due
to overload. If F opens, the engine
stops. Do not run engine until
problem is corrected.
Check fuse, and replace if open.
Fuse F6 protects the excitation cir-
cuit from damage due to overload.
If F6 opens, there will be low/no
weld and generator power output.
Check fuse, and replace if open.
Tools Needed:
3
3/8, 1/2 in
Ref. 184 780 / Ref. ST-174 733 / ST-156 468
OM-481 Page 25
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7-7. Checking And Replacing Engine Belt
Y
Stop engine, and let cool.
OFF
A V-belt drives the engine cooling
fan and alternator. To check tight-
ness of belt, proceed as follows:
RUN
Remove rear panel.
1
2
3
Fan Pulley
1
Alternator Pulley
Engine Belt
START
1/2 in (13 mm)
Maximum
Place straight edge along top of pul-
leys. Push down belt as far as it will
go, then measure distance from
belt to straight edge.
2
If less than 1/2 in (13 mm), belt is
okay. If not okay, adjust belt.
To adjust belt tension:
4
Alternator Bracket
Loosen hex nut on bracket.
Alternator Pivot Hex Nut
4
5
5
Loosen hex nut. Pivot alternator
clockwise until belt is tight. Tighten
hex nuts.
Recheck tightness of belt. Readjust
if necessary.
3
To replace belt:
Replace belt if damaged or
cracked. Replace belt as follows:
Loosen hex nuts, pivot alternator
counterclockwise, and remove
belt. Install new belt, pivot alternator
clockwise, adjust tightness, and
tighten hex nuts. Recheck tight-
ness of new belt after operating en-
gine 15 minutes and again after 20
hours.
Tools Needed:
1/2 in, 13 mm
Reinstall guard and rear panel.
Ref. ST-134 730-B / SD-131 784-A
7-8. Servicing Optional Spark Arrestor
Y
1
Stop engine and let cool.
Spark Arrestor
OFF
2
Cleanout Plug
RUN
Remove plug and remove any dirt
covering cleanout hole.
3
Exhaust Pipe
Start engine, and run at idle speed
to blow dirt out cleanout hole. If
nothing blows out of hole, briefly
cover end of exhaust pipe.
START
3
1
2
Y
Stop engine and let cool.
Reinstall cleanout plug.
Tools Needed:
3/8 in
ST-800 463-A / Ref. ST-131 784-A
OM-481 Page 26
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7-9. Adjusting Overspeed Shutdown Valve
Y
Stop engine, and let cool.
OFF
The overspeed shutdown valve
protects the engine from damage
due to high engine speed. If the en-
gine stops, the valve may be
closed.
RUN
Shutdown speed is between 1950
and 2100 rpm. Use a tachometer to
check shutdown speed as follows:
START
10
9
8
Open right side door and remove
rear panel.
1
2
3
Air Cleaner
Hose Into Air Cleaner
Hose Clamp
2
Loosen clamp and remove hose.
3
4
5
6
Plastic Cap
High Speed Stop Screw
Lock Nut
1
Remove plastic cap from screw.
Loosen nut. Turn screw out (toward
front of engine) several turns.
7
8
Speed Control Lever
Overspeed Shutdown Valve
Start engine and increase speed by
moving lever toward high speed
stop screw. Note engine rpm when
valve closes and stops engine.
If shutdown speed is not between
1950 and 2100 rpm, adjust as
follows:
9
Lock Nut
Engine End
10 Valve Adjustment Screw
Loosen nut and turn screw one turn
(clockwise to increase and counter-
clockwise to decrease shutdown
rpm). Tighten nut.
Check shutdown speed and repeat
adjustmentif needed.
Y
Stop engine.
Turn high speed stop screw in until
screw touches lever. Tighten lock
nut on screw and reinstall plastic
cap.
7
Install hose and hose clamp. Install
rear panel and close side door.
6
5
4
If necessary, adjust engine speed
according to Section 7-5
Tools Needed:
3/8 in
OM-481 Page 27
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7-10. Troubleshooting
A. Welding
Trouble
Remedy
Be sure Ampere Range switch is not set between positions.
Disconnect equipment from generator power receptacles during start-up.
Reset circuit breaker CB3 and/or CB4 (see Section 7-6).
No weld output.
Place A/V Control switch in Panel position, or place switch in Remote position and connect remote control
to Remote A/V Control receptacle RC3 (see Sections 4-7 and 4-8).
Place Output (Contactor) switch in On position, or place switch in Remote position and connect remote
contactor to optional Remote 14 receptacle RC3 or terminal strip 3T (see Sections 4-7 and 4-8).
Check and secure connections to Remote 14 receptacle or terminal strip 3T (see Sections 4-7 and
4-8).
Check fuse F6, and replace if necessary (see Section 7-6).
Have Factory Authorized Service Agent check brushes and slip rings, and circuit boards PC1 and/or
PC2.
Erratic weld output.
Check and tighten connections both inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Tighten lead connections to Ampere Range switch.
Have Factory Authorized Service Agent check circuit boards PC1 and/or PC2.
Check engine speed, and adjust if necessary (see Section 7-5).
Check CC/CV switch position.
High or low weld output voltage.
Wire feeder not operating.
If low weld output, check fuse F6, and replace if necessary (see Section 7-6).
Have Factory Authorized Service Agent check circuit board PC1.
Reset circuit breaker CB3 and/or CB4 (see Section 7-6).
Check and secure connections to Remote 14 receptacle or terminal strip 3T (see Sections 4-7 and
4-8).
Repair or replace wire feeder.
No amperage control or voltage control. Place Amperage/Voltage Control switch in correct position.
Check connections to optional Remote 14 receptacle RC3 and terminal strip 3T (see Sections 4-7 and
4-8).
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV regulator board PC2.
Set Ampere Range switch to highest range.
Low CV weld output.
Min or max CV weld output only.
Check position of Amperage/voltage control and Amperage/Voltage Control switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check optional CV regulator board PC2.
OM-481 Page 28
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B. Generator Power Trouble
Trouble
Remedy
Reset circuit breaker CB1 and/or CB2 (see Section 6-1).
Check fuse F6, and replace if necessary (see Section 7-6).
Have Factory Authorized Service Agent check brushes and slip rings.
Check engine speed, and adjust if necessary (see Section 7-5).
No output at 120 volt ac receptacles.
Low or high generator power output
voltage at 120 volt ac receptacles.
If low generator power output, check fuse F6, and replace if necessary (see Section 7-6).
C. Engine
Trouble
Remedy
Engine does not start.
Check fuel level (see Section 4-4).
Check battery, and replace if necessary.
Check oil level. Engine stops if oil temperature is too high or oil pressure is too low.
Check fuse F, and replace if necessary (see Section 7-6).
Check engine battery charging system according to engine service manual.
If Check Cooling System/Alternator light is on, check and replace engine belt.
Check oil level. Engine stops if oil temperature is too high or oil pressure is too low.
Check fuse F, and replace if necessary (see Section 7-6).
Engine suddenly stops.
Check engine speed. Optional overspeed shutdown stops engine if speed exceeds normal rpm (see
Section 7-9).
Engine uses oil during run-in period;
wetstacking occurs.
Dry engine.
Engine does not stop when Engine
Have Factory Authorized Service Agent check diode D9
Control switch is placed in Off position.
Battery discharges between uses.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
OM-481 Page 29
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SECTION 8 – ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram For Welding Generator
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194 139-B
OM-481 Page 31
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SECTION 9 – RUN-IN PROCEDURE
run_in1 8/01
9-1. Wetstacking
Y
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1
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.
2
. Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generatoris kept loaded during
run-in.
1
2
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.
OM-481 Page 32
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9-2. Run-In Procedure Using Load Bank
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
4
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
1
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.
2
Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3
Weld Cables
Connect 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.
3
Set load bank switches and then
adjust generator A/V control so load
equals rated voltage and current of
generator (see nameplate, rating
label, or the specifications section
in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generatoris loaded properly.
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
ing run-in; add oil if needed.
After one hour (minimum) place A/V
control in minimum position, then
turn off load bank to remove load.
Run engine several minutes at no
load.
Y
Stop engine and let cool.
4
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-481 Page 33
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9-3. Run-In Procedure Using Resistance Grid
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2
Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3
Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4
5
Voltmeter
Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
5
3
Start engine and run for several
minutes.
Set grid switches and then adjust
generator A/V control so load
equals rated voltage and current of
the generator (see nameplate, rat-
ing label, or the specifications sec-
tion in this manual).
4
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
+
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
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.
Y
Stop engine and let cool.
6
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-481 Page 34
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SECTION 10 – GENERATOR POWER GUIDELINES
10-1. Selecting Equipment
1
Generator Power Receptacles
– Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 6/02 – Ref. ST-159 730 / ST-800 577
0-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricityhazards.
1
2
3
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
insulated copper wire.
1
2
Y
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
GND/PE
3
Electrically bond generator
frame to vehicle frame by
metal-to-metalcontact.
S-0854
OM-481 Page 35
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10-3. Grounding When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
10-4. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
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 10-8).
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-481 Page 36
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10-5. 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
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
Fan Duty
550
650
800
1100
10-6. 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-481 Page 37
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10-7. 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
600
Circular Saw
Table Saw
6-1/2 in
7-1/4 in
8-1/4 in
9 in
500
500
900
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
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
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
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
1300
OM-481 Page 38
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10-8. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
Motor Voltage
1/4
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
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.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
10-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2
5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
2
Ref. ST-800 396-A / S-0625
OM-481 Page 39
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10-10. Typical Connections To Supply Standby Power
Y
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
3
4
Fused
Disconnect
Switch
Utility
Electrical
Service
Welding
Generator
Output
Transfer Switch
(If Required)
5
Essential
Loads
Y
Y
Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
es.
restored.
Properly install and ground this Install correct switch (customer-supplied).
equipment according to its Owner’s Switch rating must be same as or greater
Manual and national, state, and local
codes.
than the branch overcurrent protection.
3 Fused Disconnect Switch
5 Essential Loads
. Customer-supplied equipment is re-
quired if generator will supply standby
power during emergencies or power out-
ages.
Install correct switch (customer-supplied) if
required by electrical code.
Generatoroutput may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
4 Welding Generator Output
Generator output voltage and wiring must be requirements, connect only essential loads
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. – See Sec-
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
age and wiring.
tion 10-4).
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-481 Page 40
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10-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
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)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
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)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
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)
4
6
8
10
12
14
5
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)
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)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
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-481 Page 41
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SECTION 11 – PARTS LIST
8
9
10
11
14
13
7
15
12
16
17
6
5
Fig 11-2
1
Fig 11-4
2
18
3
4
19
20
21
22
64
65
66
99
98
67
70
65 97
68
96
65
95
71
66
94
72
73
93
76
75
65
69
66
92
74 73 72
77
Fig 11-3 90
89
88
87
85
84
83
5
5
78
81
82
80
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
79
not available unless listed.
Figure 11-1. Main Assembly
OM-481 Page 42
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28
27
26
29
25
24
23
30
31
30
54
32
33
37
63
34
35
62
36
38
39
46
47
48
49
61
100
50
51
52
53*
56
41
42
58
57
55
59
43
47
48
40
44
45
60(Fig. 11–5)
ST-134 499-H
OM-481 Page 43
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 11-1. Main Assembly
Quantity
. . . 1 . . . . . . . . . . . . . Fig 11-2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . Fig 11-4 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 087 341 . . BUMPER, door 1.000 OD x .750 high rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 4 . . . . . . . . . . . . . 010 083 . . HANGER, minerallic No. 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 026 947 . . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . 025 248 . . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . . 118 640 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 121 699 . . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . Z1 . . . . . 117 270 . . REACTOR, AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 131 188 . . FRAME, mtg reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . R3 . . . . 128 862 . . RESISTOR, WW adj 375W 50 ohm w/mtg bracket . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 089 533 . . BAND, resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . 118 643 . . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . 017 479 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . 032 453 . . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 208 353 . . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . BAT . . . . 190 896 . . BATTERY, stor 12 V 650 crk 110 rsv gp 24 low maint . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 182 276 . . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 010 460 . . STUD, stl .312-18 x 10.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . CR2 . . . 090 104 . . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 601 851 . . NUT, stl slflkg hex .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 20 . . . . . . . . . . . . . 145 023 . . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . TE4 . . . . 038 621 . . BLOCK, term 30A 4P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . . . . . . . . . 145 035 . . INSULATOR, strip term . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 170 550 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +131 688 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 057 359 . . BLANK,snap-in nylon .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 190 847 . . PLUG, protective 3.500 rd cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . 117 486 . . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . 118 073 . . CAP, rain 3.000 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 108 487 . . LABEL, warning falling equipment can cause serious injury . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . +131 752 . . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 131 186 . . PANEL, end engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 004 130 . . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 147 923 . . LABEL, warning do not run engine when door is open . . . . . . . . . . . . . . . . 2
. . . 31 . . . . . . . . . . . . +131 222 . . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 120 629 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . 119 861 . . LATCH, paddle series 300 w/lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 193 050 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 170 549 . . PANEL, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 133 067 . . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 010 863 . . CLAMP, hose 2.062-3.000clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 37 . . . . S11 . . . . . 118 067 . . SWITCH, vacuum air flow elect indicator 12-24VDC . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 089 129 . . PIPE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 133 066 . . HOSE, elb air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 045 657 . . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 046 544 . . . . PRECLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . 021 115 . . . . BAND, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . 021 114 . . . . CLAMP ASSEMBLY, cup air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . *020 319 . . . . ELEMENT, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . 021 117 . . . . WING NUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . 021 116 . . . . CAP, dust air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 004 115 . . . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 023 313 . . CLAMP, hose 3.000-3.250clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 601 945 . . SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OM-481 Page 44
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly (Continued)
. . . 48 . . . . . . . . . . . . . 071 731 . . WASHER, flat stl .656 ID x 2.250 OD x .187thk . . . . . . . . . . . . . . . . . . . . . . 4
. . . 49 . . . . . . . . . . . . . . 116 707 . . SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 602 246 . . WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 51 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 52 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 53 . . . . . . . . . . . . . 130 435 . . ENGINE, deutz dsl elec (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . 066 271 . . . . V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 131 208 . . STOP, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 014 . . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 010 021 . . CLAMP, stl cush .562dia x .343mtg hole (ground load support) . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 602 247 . . WASHER, flat stl sae .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 159 013 . . FITTING, pipe stl elbow M 1/2tbg x .500NPT . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 159 012 . . HOSE, oil drain 11.000 3/4 swivel fem 1/2MNPT . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . 118 452 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . 034 116 . . CLAMP, stl cush .625dia x .468mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . 131 322 . . SHUTDOWN KIT, rsv type governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . Fig 11-5 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . 166 805 . . BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . 132 712 . . PIPE, muffler extension elb 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . 119 797 . . BAFFLE, air manifold exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . 089 351 . . FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . 134 835 . . HOSE, SAE .312 ID x .560 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 11ft
. . . 66 . . . . . . . . . . . . . 172 071 . . CLAMP, hose .520-.605clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . 67 . . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elb M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . 117 227 . . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . 192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . 206 297 . . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . 092 434 . . SCREW, stl hexhd .625-11 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 72 . . . . . . . . . . . . . 039 599 . . FITTING, brs barbed M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 73 . . . . . . . . . . . . . . 119 486 . . TUBE, pick-up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 74 . . . . . . . . . . . . . 601 965 . . SCREW, cap stl hexwhd slflkg .375-16 x 1.000 . . . . . . . . . . . . . . . . . . . . . . 4
. . . 75 . . . . . . . . . . . . +159 014 . . BASE, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . 602 887 . . . . FITTING, pipe brs plug hexhd 1/4NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 77 . . . . . . . . . . . . . 131 189 . . PANEL, firewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . 131 127 . . BRACKET, rect RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . SR3 . . . 142 505 . . RECTIFIER, si 0ph 300A 400PIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 80 . . . . . . . . . . . . . 010 494 . . BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . . 116 981 . . BRACKET, rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . 131 124 . . SHIELD, heat lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . 131 125 . . SHIELD, heat lower LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . 131 123 . . SHIELD, heat upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . SHUNT . . 072 426 . . SHUNT, meter 50MV 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . . Deleted
. . . 87 . . . . . . . . . . . . . 122 354 . . GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 107 343 . . GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . 024 035 . . CAP, tank fuel 2 in IPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . ♦134 234 . . CAP, flame arrestor tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . Fig 11-3 . . PANEL, front lower w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . 134 792 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . +127 304 . . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . 602 213 . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 95 . . . . . . . . . . . . . 601 872 . . NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 96 . . . . . . . . . . . . . 121 823 . . LABEL, warning do not lift from this end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . 146 358 . . SENDER, fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . 167 298 . . VENT, fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-481 Page 45
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Figure 11-1. Main Assembly (Continued)
. . . 99 . . . . . . . . . . . . . . 118 790 . . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 089 256 . . CLAMP, stl cush 1.750dia x .531mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 137 610 . . BUS BAR, neg term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 131 243 . . BUS BAR, pos term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 131 750 . . BUS BAR, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . 165 785 . . HOSE, air cleaner 2.500 id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦Part of 042 185 Optional FA-4 Flame Arrestor – Strainer Fuel Cap.
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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INCLUDES
ITEM 4
6
7
6
25
27
26
8
24
23
9
10
2
4
21
20
11
9
16
17
12
18
15
19
14
13
ST-134 500-A
Figure 11-2. Panel, Front w/Components
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Item
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Mkgs.
Part
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Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 1)
. . . 1 . . . . . S3 . . . . 131 213 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . 118 340 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . R1 . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . S4,5 . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . S6 . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S1 . . . . 176 606 . . SWITCH, ignition 4 posn w/out handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and serial number) . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 11 . . . . . . . . . . . . . . 119 014 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . FG . . . . . 118 066 . . GAUGE, fuel elec 12V neg grd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . A1 . . . . . 118 060 . . METER, amp DC 60-0-60 2.250dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30 PSI preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 129 837 . . GAUGE/SWITCH, temp oil mech 250deg setting . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . HM . . . . . 118 058 . . METER, hour 12-24VDC 2.250dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 082 788 . . HOLDER, light ind only bayonet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . PL1,3 . . . *048 155 . . BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 090 231 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . A2 . . . . 164 875 . . METER, amp DC 50MV 0-1K scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . V1 . . . . 164 872 . . METER, volt DC 0-100 scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-481 Page 47
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9
8
7
1
6
10
5
4
11
3
2
12
13
15
14
16
17
18
19
9
18
22 21 20
23
25
24
1
ST-134 501-B
Figure 11-3. Panel, Front Lower w/Components
OM-481 Page 48
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-3. Panel, Front Lower w/Components (Fig 11-1 Item 90)
. . . 1 . . . . . . . . . . . . . 038 612 . . TERMINAL ASSEMBLY, pwr output (consisting of) . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 601 840 . . . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . . . . 601 839 . . . . NUT, brs hex .500-13 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 038 847 . . . . BUS BAR, term pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . Neg/Pos . . 038 613 . . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 038 900 . . . . STUD, brs .500-13 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . 602 247 . . . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 605 787 . . . . WASHER, lock stl intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 601 976 . . SCREW, cap stl hexhd .500-13 x 1.500 (bus bar to terminal) . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 044 942 . . NUT, locking .500-13 (bus bar to terminal) . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . C1,2 . . . 136 736 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 131 122 . . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . CB1,2 . . +139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . 2
. . . 12 GFCI1, GFCI2 151 981 . . RECEPTACLE, str dx grd 2p3w 15/20a 125v *5–15r gfi modified . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 073 690 . . PLUG, str grd armd 2P3W 15A 125V Arrow Hart 5965V
. . . . . . . . . . RC1 . . ♦604 103 . . RECEPTACLE, str dx grd 2P3W 15A 250V . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 025 234 . . PLUG, str grd 2P3W 15A 250V Arrow Hart 5666V
. . . 13 . . . VR1/R4 . . 046 819 . . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . RC3 . . . 143 976 . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 079 534 . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . 134 734 . . CONNECTOR, circ 14 pin plug Amp 213571-2
. . . . . . . . . . . . . . . . . . . 134 731 . . CONNECTOR, circ pin push-in 14-18ga Amp 213603-1
. . . . . . . . . . . . . . . . . . . 079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 or
. . . . . . . . . . . . . . . . . . . 143 922 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
. . . 15 . . . . . . . . . . . . . 020 279 . . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . CB3,4 . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 17 . . . . . C3 . . . . . 113 142 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . C4-11 . . . 138 695 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 19 . . . . . 3T . . . . 038 601 . . BLOCK, term 30A 9P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 083 030 . . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 010 915 . . WASHER, flat brs .250 ID x .625 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . 5
. . . 22 . . . . . . . . . . . . . 601 836 . . NUT, brs hex .250-20 jam hvy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . . . . . . . . . . 010 916 . . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating lower (order by model and serial number) . . 1
. . . 25 . . . . . . . . . . . . . 170 391 . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+Circuit Breakers (CB1,2) and Receptacle (RC2) remain the same for 042 943 Optional Duplex Receptacle Kit 240V.
♦Part of 042 943 Optional Duplex Receptacle Kit 240V.
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-481 Page 49
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 11-4. Control Box (Fig 11-1 Item 2)
. . . 1 . . . . . 2T . . . . 129 939 . . BLOCK, term 10A 19P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 187 013 . . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . CR1 . . . 052 603 . . RELAY, encl 110VDC DPDT 10A 120VAC 8 pin flange mtg . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 020 225 . . CLAMP, nyl .875 clamp dia x .500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . MS1 . . . . 118 072 . . SWITCH, magnetic shutdown 12VDC (consisting of) . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . F . . . . . *048 317 . . . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 122 216 . . CONNECTOR, blk 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . 1T . . . . 098 828 . . BLOCK, term 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . SR1 . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . D1, D9 . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . PC2 . . . 145 207 . . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG2 . . . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . 8
. . . 11 . . . . . . . . . . . . . 134 201 . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 12 . . . . PC1 . . . 166 203 . . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG1 . . . 135 275 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 114 066 . . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . . . . . . . 15
. . . 13 . . . . . . . . . . . . . 603 107 . . HOSE, nprn slit bk .156 ID x .343 OD (order by ft) . . . . . . . . . . . . . . . . . . . 1ft
. . . 14 . . . . SR2 . . . 097 353 . . DIODE/SCR, bridge integ 2SCR 3 diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 172 731 . . HOLDER, fuse mintr .250 x 1.250 clip anti-pivot . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . F6 . . . . 073 426 . . FUSE, mintr gl slo-blo 5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . . 173 069 . . RELAY, encl 12VDC SPDT 30A/20A 5 pin flange mtg . . . . . . . . . . . . . . . . 1
.
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1
not available unless listed.
2
14
13
11
12
10
9
9
3
8
15
4
16
7
17
5
6
ST-134 502-B
Figure 11-4. Control Box
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-481 Page 50
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Item
No.
Part
No.
Description
Quantity
Figure 11-5. Generator (Fig 11-1 Item 60)
. . . 1 . . . . *151 299 . . BRUSH, contact elect clrg .375 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . 188 387 . . BRUSHHOLDER/BRACKET ASSEMBLY (consisting of) . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . 173 066 . . . . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . 600 270 . . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 152 044 . . . . CAP, holder brush brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . 013 367 . . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . +140 096 . . STATOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . 039 207 . . . . BAFFLE, air gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . 083 751 . . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . 024 617 . . . . RING, retaining ext 1.272 shaft x .050thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . 053 390 . . . . BEARING, ball rdl sgl row 1.370 x 2.830 x .600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . 083 748 . . . . FAN, rotor gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . 180 684 . . STATOR, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . 601 965 . . SCREW, cap stl hexwhd slflkg .375-16 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 15 . . . . . 173 068 . . ENDBELL, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.
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a
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d
w
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not available unless listed.
12
9
11
10
7
8
6
5
4
2
3
1
13
16
15
14
ST-134 503-E
Figure 11-5. Generator
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-481 Page 51
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Notes
OM-481 Page 52
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Effective January 1, 2002
(Equipment with a serial number preface of “LC” 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.
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
Remote Controls
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:
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.)
Service
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 date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
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
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
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.
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
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.
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
Grids
Maxstar 85, 140
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
Spot Welders
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Load Banks
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
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.
*
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
miller_warr 6/02
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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
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
Contact the Delivering Carrier for:
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
2002 Miller Electric Mfg. Co. 5/02
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