OM-4428
215 932K
2007−10
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
R
Big Blue 500D
R
Big Blue 600 X
(Deutz-Powered)
File: Engine Drive
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-5. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-6. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-7. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-8. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-9. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-10. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . . 28
5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . 31
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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TABLE OF CONTENTS
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . . 35
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . 39
8-3. Optional Generator Power Receptacles (Standard Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-4. Generator Power Receptacles (Export Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 9 − MAINTENANCE (DEUTZ F4L2011−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-1. Maintenance Label (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-2. Routine Maintenance (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . 46
9-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . 48
9-8. Overload Protection (Deutz F4L2011-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SECTION 10 − MAINTENANCE (DEUTZ F3L912−POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10-1. Maintenance Label (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10-2. Routine Maintenance (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . 54
10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-7. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . 56
10-9. Overload Protection (Deutz F3L912-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 11 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
11-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SECTION 12 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SECTION 13 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
13-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
13-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
SECTION 14 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SECTION 15 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2007−04
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
.
I
n
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s
s
p
e
c
i
a
l
i
n
s
t
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t
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o
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s
.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
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Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequentlyinspect input power cord for damage or bare wiring —
replace cord immediately if damaged — bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
follow all Safety Standards.
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Only qualified persons should install, operate, maintain, and
repair this unit.
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During operation, keep everybody, especially children, away.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
ELECTRIC SHOCK can kill.
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Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live when power is
on. In semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equip-
ment is a hazard.
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Do not touch live electrical parts.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
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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.
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Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
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Use AC output ONLY if required for the welding process.
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Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
If AC output is required, use remote output control if present on
unit.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
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To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
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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).
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Wear approved safety glasses with side shields even under your
welding helmet.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-4428 Page 1
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Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire haz-
ards.
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If ventilation is poor, wear an approved air-supplied respirator.
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Do not use welder to thaw frozen pipes.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
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Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
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Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
Noise from some processes or equipment can dam-
age hearing.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use ap-
proved air-supplied respirator.
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Wear approved ear protection if noise level is
high.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
ARC RAYS can burn eyes and skin.
D
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
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ImplantedMedical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
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Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
CYLINDERS can explode if damaged.
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Shielding gas cylinders contain gas under high pres-
sure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
WELDING can cause fire or explosion.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot workpiece,
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
and hot equipment can cause fires and burns. Accidental contact of
electrodeto metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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Turn face away from valve outlet when opening cylinder valve.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
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Watch for fire, and keep a fire extinguisher nearby.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-4428 Page 2
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1-3. Engine Hazards
STEAM AND HOT COOLANT can burn.
BATTERY EXPLOSION can BLIND.
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If possible, check coolant level when engine is
cold to avoid scalding.
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Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
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Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
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Stop engine before disconnecting or connect-
ing battery cables or servicing battery.
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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.
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If the engine is warm, checking is needed, and there is no over-
flow tank, follow the next two statements.
Disconnect negative (−) cable first and connect it last.
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Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
FUEL can cause fire or explosion.
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Stop engine and let it cool off before checking or
adding fuel.
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Do not add fuel while smoking or if unit is near
any sparks or open flames.
Using a generator indoors CAN KILL
YOU IN MINUTES.
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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.
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Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
Always keep nozzle in contact with tank when fueling.
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NEVER use inside a home or garage, EVEN IF
doors and windows are open.
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Only use OUTSIDE and far away from windows, doors, and
vents.
MOVING PARTS can cause injury.
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Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
BATTERY ACID can BURN SKIN and EYES.
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Stop engine before installing or connecting unit.
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Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
Have only qualified people remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
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To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
ENGINE HEAT can cause fire.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
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Do not locate unit on, over, or near combustible
surfaces or flammables.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
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Keep exhaust and exhaust pipes way from
flammables.
Block flywheel so that it will not turn while working on generator
components.
HOT PARTS can cause severe burns.
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Do not touch hot parts bare handed.
Allow cooling period before working on equip-
ment.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
EXHAUST SPARKS can cause fire.
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Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
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1-4. Compressed Air Hazards
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
BREATHING COMPRESSED AIR can
cause serious injury or death.
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Release air pressure from tools and system be-
fore servicing, adding or changing attach-
ments, or opening compressor oil drain or oil fill
cap.
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Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
COMPRESSED AIR can cause injury.
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Wear approved safety goggles.
Do not direct air stream toward self or others.
OM-4428 Page 3
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HOT METAL from air arc cutting and
gouging can cause fire or explosion.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
Stop engine and release air pressure before
servicing.
Use only genuine replacement parts from the
manufacturer.
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Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
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Do not touch hot compressor or air system
parts.
Let system cool down before touching or ser-
vicing.
1-5. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
WELDING WIRE can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
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Do not press gun trigger until instructed to do
so.
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Do not install unit near flammables.
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Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
OVERUSE can cause OVERHEATING.
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Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Lift and support unit only with proper equipment
and correct procedures.
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Do not block or filter airflow to unit.
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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.
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Put on grounded wrist strap BEFORE handling
boards or parts.
OVERHEATING can damage motors.
D
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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Turn off or unplug equipment before starting or
stopping engine.
D
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
TILTING OF TRAILER can cause injury.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
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Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
FLYING SPARKS can cause injury.
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Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
Use only genuine replacement parts from the
manufacturer.
Perform engine and air compressor mainte-
nance and service according to this manual
and the engine/air compressor (if applicable)
manuals.
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Sparks can cause fires — keep flammables away.
MOVING PARTS can cause injury.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OM-4428 Page 4
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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.
Have only qualified persons familiar with
electronic equipment perform this installation.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as micro-
processors, computers, and computer-driven
equipmentsuch as robots.
Be sure all equipment in the welding area is
electromagneticallycompatible.
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The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
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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.
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Have the installation regularly checked and maintained.
Be sure this welding machine is installed and grounded
according to this manual.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-6. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044,website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900,website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, web-
site: www.nfpa.org.
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000,website: www.nfpa.org and www. sparky.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
About Implanted Medical Devices:
ImplantedMedical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-4428 Page 5
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_2007−04fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
.
I
n
d
i
q
u
e
d
e
s
i
n
s
t
r
u
c
t
i
o
n
s
s
p
é
c
i
f
i
q
u
e
s
.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
manuelAC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra-
vailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147(voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformé-
ment à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chau-
des.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électro-
cution.
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les ris-
ques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.
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L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrementles enfants.
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UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquerune électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
D
dès que l’appareil est sur ON. Le circuit d’entrée et les circuits
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.
D
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Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
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Ne pas enrouler les câbles autour du corps.
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Ne jamais toucher les pièces électriques sous tension.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Porter des gants et des vêtements de protection secs ne compor-
tant pas de trous.
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Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
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S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
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D
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Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
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Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
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Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé-
talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
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Une tension DC importante subsiste à l’intérieur
des onduleurs après avoir coupé l’alimentation.
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Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
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Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
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Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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Ne pas toucher à mains nues les parties chau-
des.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
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Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
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Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites peu
provoquer leur éclatement. Des étincelles peuven
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Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
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Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
D
D
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À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
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Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les nor-
mes de sécurité).
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
D
D
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for-
mer des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
LES ACCUMULATIONS DE GAZ ris
quent de provoquer des blessures ou
même la mort.
D
D
D
D
Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-
ce d’étincelles incandescentes ni de flammes.
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateurd’adduction d’air homologué.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
LE BRUIT peut affecter l’ouïe.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
Le bruit des processus et des équipements peut affec
l’ouïe.
D
Porter des protections approuvés pour les ore
les si le niveau sonore est trop élevé.
OM-4428 Page 7
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D
D
Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
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.
Si des BOUTEILLES sont endomma
gées, elles pourront exploser.
D
D
D
D
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Des bouteilles de gaz protecteur contiennent du ga
sous haute pression. Si une bouteille est endomma
Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisationou de branchement de la bouteille.
gée, elle peut exploser. Du fait que les bouteilles de gaz fon
normalement partie du procédé de soudage, les manipuler ave
précaution.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
D
Seules des personnes qualifiées sont autorisées à enlever les por-
tes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.
L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.
D
Toujours porter une protection faciale, des gants
en caoutchouc et vêtements de protection lors
d’une intervention sur la batterie.
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien,débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles
de batterie.
Remettreen place les panneaux ou les dispositifs de protection et
fermer les portes à la fin des travaux d’entretien et avant de faire
démarrer le moteur.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
D
D
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Ne pas utiliser le poste de soudage pour charger les batteries ou
des véhicules de démarrage rapide.
Bloquerle volant moteur pour éviter sa rotation lors d’une interven-
tion sur le générateur.
D
D
Observer la polarité correcte (+ et −) sur les batteries.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
D
Ne pas toucher à mains nues les parties chau-
des.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
LE CARBURANT MOTEUR peut provo
quer un incendie ou une explosion.
D
D
Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
Ne pas faire le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
D
D
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
D
D
Jeter les chiffons dans un récipient ignifuge.
D
Il est préférable de vérifier le liquide de refroi-
dissementune fois le moteur refroidi pour éviter
de se brûler.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
D
Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si pré-
cisé autrement dans la section maintenance du manuel du
moteur).
DES ORGANES MOBILES peuvent pro
voquer des blessures.
D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer com-
me suivant.
D
Ne pas approcher les mains des ventilateurs,
courroies et autres pièces en mouvement.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
D
Maintenirfermés et fixement en place les portes, panneaux, re-
couvrements et dispositifs de protection.
D
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
OM-4428 Page 8
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L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
LA CHALEUR DU MOTEUR peut pro-
voquer un incendie.
D
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
D
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisi-
ble et inodore.
D
Tenir à distance les produits inflammables de l’échappement.
D
JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
D
Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
D
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
D
Rincer immédiatement les yeux et la peau à l’eau.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
Ne pas couper ou gouger à proximité de pro-
duits inflammables.
Surveillez et garder un extincteur à proximité.
D
D
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le cou-
page, gougeage et les outils pneumatiques.
D
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
L’AIR COMPRIMÉ peut provoquer
des blessures.
D
Ne pas toucher le compresseur ou d’autres
éléments du circuit air comprimé chauds.
D
D
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou
soi-même.
D
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la
maintenance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
Relâcher la pression d’air de l’outillage ou du
système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissaged’huile.
D
Arrêter le moteur et relâcher la pression avant
d’effectuer la maintenance.
D
N’utiliser que les pièces de rechange recommandées par le
constructeur.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LA CHUTE DE L’APPAREIL peut blesser.
D
Utiliser l’anneau de levage pour lever l’appareil et
les accessoires correctement installées seuls,
PAS les bouteilles de gaz. Ne pas dépasser le
poids nominal maximal de l’œilleton (voir les spé-
cifications).
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Ne lever et ne soutenir l’appareil qu’avec de
l’équipement approprié et en suivant les
procédures adéquates.
D
Ne pas surcharger l’installation électrique − s’assurer que l’ali-
mentationest correctement dimensionnée et protégée avant de
mettre l’appareil en service.
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.
OM-4428 Page 9
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UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
D
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
D
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
D
Installer convenablement le poste sur la remor-
que comme indiqué dans le manuel s’y rappor-
tant.
D
D
Ne pas laisser tourner le moteur trop lentement sous risque d’en-
dommagerle moteur électrique à cause d’une tension et d’une fré-
quence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Effectuer la maintenance et le service du moteur et du compres-
seur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’instal-
lation.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
D
L’utilisateurest tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
D
Effectuer régulièrement le contrôle et l’entretien de l’installation.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Maintenirsoigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une dis-
tance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et
l’équipementcommandé par ordinateur tel que
les robots.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
Laisser l’équipement refroidir ; respecter le fac-
teur de marche nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Ne pas obstruer les passages d’air du poste.
D
D
D
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
OM-4428 Page 10
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2-6. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
2-7. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900,site Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 de Global Engineering Documents (téléphone
1-877-413-5184,site Internet : www.global.ihs.com).
:
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-8. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa-
miné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National
Research Council a conclu : « L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiqueset champs électriques à haute fréquence représente un
risque à la santé humaine ». Toutefois, des études sont toujours en
cours et les preuves continuent à être examinées. En attendant que les
conclusions finales de la recherche soient établies, il vous serait
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-4428 Page 11
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)
1
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
S-177 571
1
+
2
3
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
2
+
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
3
DIESEL
5
6
Check oil level. Add oil if
necessary.
4
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5
7
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std.
200A
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
OM-4428 Page 12
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3-3. Symbols And Definitions
.
S
o
m
e
s
y
m
b
o
l
s
a
r
e
f
o
u
n
d
o
n
l
y
o
n
C
E
p
r
o
d
u
c
t
s
.
Fast (Run, Weld/
Power)
Stop Engine
Starting Aid
Slow (Idle)
Start Engine
Engine Oil
Engine Oil
Pressure
Battery (Engine)
Check Injectors/
Pump
Check Valve
Clearance
Protective Earth
(Ground)
Fuel
Certified/Trained
Mechanic
Positive
Negative
Volts
Welding Arc
Remote
Amperes
Panel/Local
Output
A V
Air Temperature Or
Engine
Alternating
Current
Engine
Temperature
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Single Phase
Time
Hours
Seconds
1
h
s
Read Operator’s
Manual
Do Not Switch
While Welding
Three Phase
Circuit Protector
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Electrode
Connection
G
3
Work Connection
Hertz
Hz
Rated No Load
Conventional
Load Voltage
Rated Load
Speed
Duty Cycle
X
U0
n0
U2
I
Voltage (Average)
n
I2
Rated Idle
Speed
Rated No Load
Speed
Rated Welding
Current
Current
n1
Contactor On
OM-4428 Page 14
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SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Weld
Output
Range
Maximum
Open-Circuit
Voltage
Welding
Mode
Rated Welding
Output
Generator Power
Rating
Fuel
Capacity
Engine
65 − 600 A
Standard:
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC, 50/60 Hz
(CC Models)
95
56
CC/DC
600 A, 30 Volts DC,
40% Duty Cycle
20 − 600 A
(CC/CV
Models)
DEUTZ
Deutz F4L2011
Air/Oil-Cooled, Four
Cylinder, 46.3 HP
Diesel Engine
IFC Rating
500 A, 40 Volts DC,
100% Duty Cycle
Three-Phase Generator
Option:*
Single-Phase/Three-Phase,
12/20 kVA/kW, 50/48A,
120/240 VAC, 60 Hz
25 gal
(95 L)
CV/DC
or
550 A, 40 volts DC,
60% Duty Cycle
(CC/CV
Models
Only)
Deutz F3L912,
Air-Cooled, Three
Cylinder, 41.5 HP
Diesel Engine
14 − 40 V
*In Addition To Standard
4 kVA/kW Generator Power
4-2. Dimensions, Weights, And Operating Angles
Dimensions
50 in (1270 mm)
Height
(to top of muffler)
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
Width
30-3/4 in (781 mm)
(mtg. brackets turned out)
Depth
A
65-1/8 in (1654 mm)
65-1/8 in (1654 mm)
56 in (1422 mm)
Do not exceed tilt angles or engine could
be damaged or unit could tip.
B*
C*
D*
E
Do not move or operate unit where it could
tip.
46-1/2 in (1181)
A
9-5/8 in (244 mm)
27-1/2 in (699 mm)
1 in (25 mm)
B
C
D
F
G
29-13/16in (757 mm)
H
9/16 in (14 mm) Dia.
4 Holes
H
30°
Front Panel End
*
With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
30°
20°
20°
F
Weight
E
w/ Deutz
F4L2011
No fuel: 1690 lb (767 kg)
w/fuel: 1880 lb (853 kg)
802 161-A
w/ Deutz
F3L912
No fuel: 1785 lb (810 kg)
w/fuel: 1975 lb (896 kg)
Lifting Eye Weight Rating:
2500 lb (1134 kg) Maximum
803 602
OM-4428 Page 15
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4-3. Volt-Ampere Curves For CC Models
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.
100
80
60
40
20
0
Ranges
300−Max
185−425
125−320
85−190
55−90
0
100 200 300 400 500 600 700 800 900
DC AMPERES
203 412
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 16
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4-4. Volt-Ampere Curves For CC/CV Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
Ranges
275−Max
150−525
110−390
80−240
80
60
40
20
0
50−125
1000
0
100 200 300 400 500 600 700 800 900
DC AMPERES
B. MIG Mode
100
80
60
40
20
MAX
MIN
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode
100
Ranges
50−440
35−320
25−215
15−115
80
60
40
20
0
0
100
200
300
400
500
DC AMPERES
217 811 / 203 415 / 217 810
OM-4428 Page 17
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4-6. 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 500 Amperes
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
ContinuousWelding
202 356
4-7. AC Generator Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
75 150
50 100
25 50
0
0
0
0
5
10
15
20
25
50
30
60
AC AMPERES IN 240V MODE
10
20 30 40
AC AMPERES IN 120V MODE
193 018
OM-4428 Page 19
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4-8. Optional Three-Phase Generator Curves
The ac power curves show the gen-
erator power available in amperes
at the single-phase 120/240 volt re-
ceptacle or three-phase 240 volt
terminals.
A. 12 kVA/kW Single-Phase AC Output (No Weld Load)
280
270
260
250
240
230
220
210
200
190
180
140
135
130
125
120
115
110
105
100
95
90
20
40
60
80
100
0
AC AMPERES
B. 20 kVA/kW Three-Phase AC Output (No Weld Load)
280
260
240
220
200
180
0
10
20
30
40
50
60
70
AC AMPERES
197 472 / 197 473
OM-4428 Page 20
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SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
Movement
!
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
If unit does not have GFCI re-
ceptacles,use GFCI-protected
extension cord.
OR
OR
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
.
S
e
e
f
o
r
l
i
f
t
i
n
g
e
y
e
r
a
t
-
Location/AirflowClearance
ing.
.
S
e
e
f
o
r
m
o
u
n
t
i
n
g
i
n
-
formation.
Grounding:
1
Equipment Grounding Terminal
(On Front Panel)
OR
OR
2
3
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
. Electrically bond generator
frame to vehicle frame by met-
al-to-metalcontact.
18 in
(460 mm)
18 in
Bed liners, shipping skids,
and some running gears insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equipment
grounding terminal to bare
metal on the vehicle frame as
shown.
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
Grounding
1
2
GND/PE
3
install3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712
OM-4428 Page 21
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5-2. Using Lifting Eye
1
2
3
Lifting Eye
Nut
Carriage Bolt
1
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
2
Tools Needed:
3
Ref. 802 311
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 22
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5-3. Mounting Welding Generator
!
Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
NOTICE − Do not mount unit by
supportingthe base only at the four
mounting brackets. Use cross-
supports to adequately support unit
and prevent damage to base.
2
Mounting Surface:
1
2
Cross-Supports
Mounting Brackets (Supplied)
OR
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
3
1/2 in Bolt And Washer
(Minimum − Not Supplied)
1
4
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in
install3 2007−04 803 274 / 200 864-A /803 602-B
OM-4428 Page 23
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5-4. Installing Exhaust Pipe
!
Stop engine and let cool.
. Point exhaust pipe in desired di-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
Ref. 803 604 / Ref. 215 664
5-5. Installing Optional Ether Cylinder (Deutz F3L912 Engine Only)
Stop engine.
Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
Do not use Ether Starting Aid
while engine is running.
1
Remove rubber access plug from
cover.
1
2
Ether Cylinder
Nozzle
Remove cover and clean cylinder
nozzle.
2
3
4
5
6
Clamp
Fitting
Cap
Valve
3
4
Remove cap and clean fitting.
Install cylinder on fitting. Tighten
clamp.
5
. After installing cylinder, wait at
least 10 minutes before using
to let ether particles settle and
prevent atomizer plugging.
6
Put cap on fitting when cylinder is
removed.
Reinstall plug in cover.
ether1 7/96 − 153 382-A / Ref. 215 664
OM-4428 Page 24
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5-6. Activating The Dry Charge Battery (If Applicable)
Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
1
2
Vent Caps
2
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
1
3
Well
Fill each cell with electrolyte to
bottom of well (maximum).
Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
4
Battery Charger
Read and follow all instruc-
tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
4
. When electrolyte is low, add
only distilled water to cells to
maintainproper level.
5 A For 30 Minutes
OR
+
−
30 A For 12 Minutes
Tools Needed:
drybatt1 6/05 − S-0886
5-7. Connecting The Battery
.
R
e
i
n
s
t
a
l
l
c
o
v
e
r
a
f
t
e
r
c
o
n
n
e
c
t
i
n
g
b
a
t
t
e
r
y
.
Connect negative (−) cable last.
+
−
Tools Needed:
1/2 in
Ref. 215 664 / 803 605 / S-0756-C
OM-4428 Page 25
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5-8. Engine Prestart Checks
Full
Diesel
Deutz F4L2011 Engine
Full
Full
Diesel
Deutz F3L912 Engine
Full
Ref. 803 657 / 803 658
If unburned fuel and oil collect in exhaust
Oil
.
C
h
e
c
k
a
l
l
e
n
g
i
n
e
f
l
u
i
d
s
d
a
i
l
y
.
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil. The
Automaticshutdown system stops engine if
oil pressure is too low or coolant tempera-
ture is too high.
Fuel
. To improve cold weather starting:
Use optional Starting Aid switch (see
NOTICE − Do not use gasoline. Gasoline
will damage engine.
Keep battery in good condition. Store
battery in warm area.
Add fresh diesel fuel before starting to pre-
vent air from entering the fuel system (see
enginemaintenance label for fuel specifica-
tions). Leave filler neck empty to allow room
for expansion.
.
T
h
i
s
u
n
i
t
h
a
s
a
l
o
w
o
i
l
p
r
e
s
s
u
r
e
s
h
u
t
-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel in-
formation.
Do not run out of fuel or air may enter fuel
system and cause starting problems. See
enginemanual to bleed air from fuel system.
Use correct grade oil for cold weather
Follow run-in procedure in engine manual.
OM-4428 Page 26
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5-9. Connecting To Weld Output Terminals
Stick and TIG Welding
MIG and FCAW Welding
For Stick and TIG welding Direct Current Elec-
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) on CC/CV models,
connect wire feeder cable to Positive (+) termi-
nal on left and work cable to Negative (−) ter-
minal on right. Use Process/Contactor switch
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.
!
Stop engine.
1
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
2
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminaland secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
1
Tools Needed:
3/4 in
2
6
3
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Correct Installation
Incorrect Installation
803 602 / 803 778-A
OM-4428 Page 27
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5-10. 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
Stop engine before
connecting to weld
output 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
500
2 (35)
1 (50)
1 (50)
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)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
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)
2/0 (70)
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)
*Chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm for metric use
S-0007-F
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-11. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1
Ref. 154 862-A / 048 720-K / 803 602
OM-4428 Page 28
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5-12. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts ac. Protected by sup-
plementary protector CB5.
24 VOLTS AC
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D
Remote control circuit common.
New! LDR-14 long
distance remote
(includes 120 V
receptacle)
REMOTE
OUTPUT
CONTROL
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz
ac. Protected by supplementary
protector CB6.
I
OR
115 VOLTS AC
Contact closure to I completes
115 volt ac contactor control
circuit.
J
K
Chassis common.
GND
Ref. 803 602
NEUTRAL
G
Circuit common for 24 and 115
volt ac circuit.
*The remaining sockets are not used.
Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
OM-4428 Page 29
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Engine Starting Controls
Starting Aid Switch
gine is running, and about 12 volts dc when 10 Stick/TIG Selection Switch
the engine is stopped.
1
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
6
Engine Coolant Temperature Gauge
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
2
Engine Control Switch
7
Engine Oil Pressure Gauge
Use switch to start and stop engine.
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
To Start:
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
NOTICE − Do not use ether. Using ether
voids warranty.
Weld Controls
.
M
a
x
O
C
V
C
o
n
t
r
o
l
C
i
r
c
u
i
t
:
T
h
i
s
u
n
i
t
h
a
s
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
a max OCV control circuit that resets Am-
perage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust open-
circuit voltage.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
11 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
Connect optional remote control to RC13
panel or remote amperage control. For re-
mote control, place switch in Remote position
and connect remote control to Remote Am-
perage Adjust receptacle RC13 (see Sec-
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
To Stop: turn Engine Control switch to Off
position.
12 Polarity Switch (Optional)
Engine Gauges And Meters
8
Ampere Range Switch
NOTICE − Do not switch under load.
Use hour meter to monitor engine run time to Use switch to select weld amperage range.
NOTICE − Do not switch under load.
3
Engine Hour Meter
Use switch to change weld output. Select ei-
ther DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
help schedule maintenance.
For most welding applications, use lowest
amperagerange possible to help prevent arc
outages.
4
Fuel Gauge
Weld Meters
Use gauge to check fuel level.
9
AmperageAdjust Control
13 AC/DC Voltmeter (Optional)
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run posi-
tion.
Control adjusts amperage within range se-
lected by Ampere Range switch. Weld output
would be about 180 A DC with controls set as
shown (50% of 150 to 330 A).
Voltmeterdisplays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
5
Battery Voltmeter (Optional)
14 AC/DC Ammeter (Optional)
.
T
h
e
n
u
m
b
e
r
s
a
r
o
u
n
d
t
h
e
c
o
n
t
r
o
l
a
r
e
f
o
r
Use gauge to check battery voltage and moni-
tor the engine charging system. The meter
should read about 14 volts dc when the en-
reference only and do not represent an Ammeter displays amperage output of the
actual percentage value.
unit.
OM-4428 Page 31
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6-3. Remote Amperage Control On CC Models (Optional)
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1
In Example:
Range = 115 to 330 A DC
Example: Combination Remote Amperage Control (Stick)
Percentage Of Range = 50%
Max = About 240 A DC (50% of 150 to 330)
Max (240 A DC)
Min (84 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
Ref. 154 862-A / Ref. 215 663 / 803 602
6-4. Weld Control/Arc Condition Information Label
. Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.
212 944-A
OM-4428 Page 32
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Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 33
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Engine Starting Controls
Starting Aid Switch
tor the engine charging system. The meter
should read about 14 volts dc when the en-
gine is running, and about 12 volts dc when
the engine is stopped.
. The numbers around the control are for
reference only and do not represent an
actual percentage value.
1
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
11 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
6
Engine Coolant Temperature Gauge
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
2
Engine Control Switch
Use switch to select front panel or remote
voltage/amperage control. For remote con-
trol, place switch in Remote position and con-
nect remote control to Remote 14 receptacle
Use switch to start engine, select engine
speed ( if unit has auto idle option), and stop
engine.
7
Engine Oil Pressure Gauge
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
12 Polarity Switch (Optional)
NOTICE − Do not switch under load.
Use Polarity switch to change weld output.
Select either DC Electrode Positive (DCEP)
or DC Electrode Negative (DCEN).
Weld Controls
To Start:
8
Process/Contactor Switch
NOTICE − Do not use ether. Using ether
voids warranty.
switch information.
13 Polarity/AC Switch (Optional)
!
Electric shock can kill.
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
9
Ampere Range Switch
Do not use AC output in damp areas,
if movement is confined, or if there is
a danger of falling.
NOTICE − Do not switch under load.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Use switch to select weld amperage range.
Use AC output ONLY if required for the
welding process. If AC output is re-
quired, use remote output control if
present on unit.
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
NOTICE − Do not switch under load.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
Use Polarity/AC switch to select AC or DC
weld output and DC weld output polarity. For
Direct Current Electrode Negative (DCEN),
turn switch to − (Negative) position. For Direct
Current Electrode Positive (DCEP), turn
switch to + (Positive) position. For weld pro-
cesses that require alternating current (AC),
use AC position.
To Stop: turn Engine Control switch to Off
position.
For most welding applications, use lowest
amperagerange possible to help prevent arc
outages.
Engine Gauges And Meters
10 Voltage/AmperageAdjust Control
3
Engine Hour Meter
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Re-
mote position, control limits the remote am-
peragein TIG mode, but has no effect in Stick
and MIG modes.
Use hour meter to monitor engine run time to
help schedule maintenance.
Weld Meters
4
Fuel Gauge
14 AC/DC Voltmeter (Optional)
Use gauge to check fuel level.
Voltmeterdisplays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run posi-
tion
15 AC/DC Ammeter (Optional)
5
Battery Voltmeter (Optional)
Weld output would be about 250 A DC with Ammeter displays amperage output of the
controls set as shown (50% of 110 to 390 A). unit.
Use gauge to check battery voltage and moni-
OM-4428 Page 35
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7-3. Process/Contactor Switch On CC/CV Models
1
Process/Contactor Switch
Weld output terminals are ener-
gized when Process/Contactor
switch is in an Weld Terminals
Always On position and the en-
gine is running.
1
DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the Re-
mote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table be-
Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides addition-
al amperage during low voltage (short
arc length conditions) to prevent “stick-
ing” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.
. Place switch in Weld Terminals Al-
ways On - Stick position when us-
ing optional three-phase generator
. The engine auto idle option does
not work in the Remote On/Off
Switch Required-TIG mode.
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle (Optional)
Remote On/Off Switch Re-
quired − TIG, HF Required
Or Scratch Start TIG
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Not Active
Remote On/Off Switch
Stick (SMAW) With Remote On/Off
MIG (GMAW)
At Remote 14 Receptacle
At Remote 14 Receptacle
Electrode Hot
Active
Active
Active
Active
Active
Required − Stick
Remote On/Off Switch
Required − CV Feeder
Using Remote
Weld Terminals Always On −
MIG (GMAW)
Wire
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Weld Terminals Always On −
Electrode Hot
Stick
Weld Terminals Always On −
TIG Scratch Start (GTAW)
Electrode Hot
TIG, Scratch Start
OM-4428 Page 36
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7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 110 to 390 A DC
Min = 110 A DC
Example: Combination Remote Amperage Control (Stick)
Max = 390 A DC
Max (390 A DC)
Min (110 A DC)
Set Remote
Process
Set V/A
Adjust Switch
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 35 to 320 A DC
Example: Combination Remote Amperage Control (TIG)
Percentage Of Range = 50%
Min = 35 A DC
Max = About 178 A DC (50% of 35 to 320)
Max (178 A DC)
Min (35 A DC)
Set Remote
Process
Set V/A
Adjust Switch
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 215 664 / Ref. 803 602
OM-4428 Page 37
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SECTION 8 − OPERATING AUXILIARY EQUIPMENT
8-1. 120 Volt And 240 Volt Receptacles
1
2
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
1
2
3
4
. At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
3
4
Supplementary Protector CB1
Supplementary Protector CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset.
. If a supplementary protector
continues to open, contact
Factory Authorized Service
Agent.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
-
fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-4428 Page 38
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8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
.
P
l
a
c
e
P
r
o
c
e
s
s
/
C
o
n
t
a
c
t
o
r
s
w
i
t
c
h
in Electrode Hot - Stick position
when using three-phase genera-
1
2
Single-Phase Power Connection
Single-Phase Generator Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
2
Supplementary Protector CB7
CB7 protects single-phase recep-
tacle RC5 and the load wires from
overload. If CB7 opens, all three-
phase generator output stops and the
receptacle does not work.
Three-Phase Generator Power
Single
Phase
1
Three
Phase
3
Three-Phase Power Connection
AC
Stop engine.
Output
Power and weld outputs are
live at the same time. Discon-
nect or insulate unused
cables.
Volts
120/240
240
!
Close panel opening
if no connections are
made to generator.
Amps
KVA/KW
50
12
48
20
Frequency
Engine Speed
60 Hz
1850 RPM
. Have qualified person install ac-
cording to circuit diagram and
Generator Power Guidelines
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
Remove generator power panel
mountingscrews. Tilt panel forward.
93
3
4
5
6
Lead 93
Lead 92
Lead 91
91
Remove plug
before inserting
leads. Reinstall
bushing.
90
92
Lead 42 (Circuit Grounding
Lead)
4
3
7
8
9
Lead 90 (Neutral)
Rear Of Panel
5
6
Isolated Neutral Terminal
Jumper Lead 42
91
92
93
10 Grounding Terminal
2
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
nected from neutral to meet applica-
ble electrical codes.
12
7
Lead 42 connects to front panel
Ground stud.
10
11
11 User-Supplied Leads
12 Supplementary Protector CB7
User Terminals
Connect user-supplied leads to ter-
minals on CB7 and to the isolated
neutral terminal and grounding termi-
nal as necessary.
!
Close panel
opening if no
connections
are made to
generator.
9
8
.
C
B
7
p
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o
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e
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s
s
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e
-
p
h
a
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r
e
-
240V
240V
ceptacle RC5 and the load wires
from overload. If CB7 opens, all
three-phase generator output
stops and the receptacle does
not work.
120V
1-Phase
3-Phase
120V
Tools Needed:
240V
Reinstall generator power panel.
240V
Ref. 197 399 / 802 332-B / 803 655
OM-4428 Page 39
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8-3. Optional Generator Power Receptacles (Standard Models)
1
2
3
4
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 16 A AC European
Receptacle RC1
European Receptacle
1
2
5
6
240 V 15 A AC Australian
Receptacle RC1
240 V 15 A AC South African
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
.
A
t
l
e
a
s
t
o
n
c
e
a
m
o
n
t
h
,
r
u
n
e
n
-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
Australian Receptacle
5
1
3
5
6
Supplementary Protector CB2
Supplementary Protector CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset.
6
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset.
. If a supplementary protector
continues to open, contact
Factory Authorized Service
Agent.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
-
fected by weld output.
South African Receptacle
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
5
1
4
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624
OM-4428 Page 40
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8-4. Generator Power Receptacles (Export Models)
4
1
2
5
3
Ref. 204 258
CB1 protects RC1 and the generator wind- Maximumoutput is 4 kVA/kW from RC1 and
ing from overload. If CB1 opens, RC1 and 2.2 kVA/kW from RC2 or RC3. Maximum
RC2 do not work. Place switch in On position output from all receptacles is 4 kVA/kW.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
f
e
c
t
e
d
b
y
w
e
l
d
output.
1
2
3
130 V 32 A AC Receptacle RC1
220 Volt 16 A AC Receptacle RC2
130 Volt 16 A AC Receptacle RC3
to reset.
Combinedoutput of receptacles is limited to
4 kVA/kW output of generator. If maximum
output is exceeded, auxiliary equipment will
stop or not run properly.
EXAMPLE: If 20 A is drawn from RC1, only
8 A is available at each of the other
receptacles.
CB2 protects RC2, and CB3 protects RC3
from overload. If a supplementary protector
opens, the receptacle does not work. Place
switch in On position to reset.
Receptacles supply 60 Hz single-phase
power at weld/power speed.
4
5
Supplementary Protector CB1
Supplementary Protectors CB2 And
CB3
.
I
f
a
s
u
p
p
l
e
m
e
n
t
a
r
y
p
r
o
t
e
c
t
o
r
c
o
n
t
i
n
u
e
s
to open, contact Factory Authorized (110 V x 20 A) + ( 110 V x 8 A) + (110 V x 8
Service Agent.
A) = 4 kVA/kW.
OM-4428 Page 41
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9-2. Routine Maintenance (Deutz F4L2011-Powered Units)
Stop engine before maintaining.
. See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
Recycle engine
fluids.
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference
* To be done by Factory Authorized Service Agent
Every
8
Hours
FUEL
WATER
n
F
u
e
l
/
W
a
t
e
r
S
e
p
a
r
a
t
o
r
n
F
u
e
l
L
e
v
e
l
n
O
i
l
L
e
v
e
l
~
O
i
l
,
F
u
e
l
S
p
i
l
l
s
Every
50
Hours
~
W
e
l
d
T
e
r
m
i
n
a
l
s
Every
100
Hours
~
B
a
t
t
e
r
y
T
e
r
m
i
n
a
l
s
n
A
i
r
C
l
e
a
n
e
r
H
o
s
e
s
n
L
’
é
l
é
m
e
n
t
d
u
f
i
l
t
r
e
à
a
i
r
Every
250
Hours
Engine
1/2 in.
Manual,
(13 mm)
l
U
n
r
e
a
d
a
b
l
e
L
a
b
e
l
s
n
F
a
n
B
e
l
t
T
e
n
s
i
o
n
~
C
o
o
l
i
n
g
S
y
s
t
e
m
n
~
S
p
a
r
k
A
r
r
e
s
t
o
r
Every
500
Hours
n
l
W
e
l
d
C
a
b
l
e
s
Every
1000
Hours
Engine
Manual
Z
O
i
l
Z
O
i
l
F
i
l
t
e
r
Z
F
u
e
l
F
i
l
t
e
r
FUEL
OR
SLUDGE
n
n
~ Slip Rings*
Brushes*
~
I
n
s
i
d
e
U
n
i
t
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
~
D
r
a
i
n
S
l
u
d
g
e
l
Every
3000
Hours
~
I
n
j
e
c
t
o
r
s
*
Every
6000
Hours
or 5
Years
n
l
E
n
g
i
n
e
T
i
m
i
n
g
B
e
l
t
OM-4428 Page 43
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9-3. Checking Generator Brushes
!
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
materialis at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
OM-4428 Page 44
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9-4. Servicing Air Cleaner (Deutz F4L2011-Powered Units)
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damagecaused by using a damaged ele-
ment is not covered by the warranty.
1
3
4
2
. The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
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.
1
2
3
4
5
Housing
Keep nozzle
2 in (51 mm)
from element.
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
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-4428 Page 45
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9-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F4L2011-Powered Units)
1
Stop engine and let cool.
Spark Arrestor Muffler
Cleanout Plug
2
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
2
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 215 664
OM-4428 Page 46
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9-6. Adjusting Engine Speed (Deutz F4L2011-Powered Units)
Stop engine and let cool.
Engine speed is factory set and
should not require adjustment. Af-
ter tuning engine, check engine no
load speed with a tachometer or fre-
quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:
Start engine and run until warm.
On CC Models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick − Elec-
trode Hot position.
Standard Models:
1
Engine Speed Adjustment
Screw
1850 rpm Max.
(61.6 Hz)
2
Locking Nut
1250 rpm
(41.5 Hz)
Loosen nut. Turn screw until engine
runs at weld/power speed. Tighten
nut.
.
D
o
n
o
t
s
e
t
e
n
g
i
n
e
s
p
e
e
d
h
i
g
h
e
r
than specified.
Models With Automatic Idle
(Optional)
3
4
Throttle Rod
Locknut
Loosen locknuts. Place engine
control switch in Run/Idle position.
Standard Models
Turn throttle rod until engine runs at
idle speed. Tighten locknuts.
5
Engine Speed Adjustment
Screw
6
Locknut
2
1
Place engine control switch in Run
position.
Loosen locknut. Turn screw until
engine runs at weld/power speed.
Tighten locknut.
.
D
o
n
o
t
s
e
t
e
n
g
i
n
e
s
p
e
e
d
h
i
g
h
e
r
than specified.
Stop engine.
Models With Automatic Idle (Optional)
Close door.
4
3
5
6
Tools Needed:
3/8, 7/16 in
803 657
OM-4428 Page 47
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9-7. Servicing Fuel And Lubrication Systems (Deutz F4L2011-Powered Units)
Tools Needed:
3
4
5
6
2
7
1
803 657
maintenance label for oil/filter change in-
formation.
To replace secondary fuel filter:
See engine manual.
Close doors.
Stop engine and let cool.
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
To drain water from fuel system:
To drain sludge from fuel tank:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
1
2
3
4
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
To replace primary fuel filter:
Primary Fuel Filter (Fuel/Water Sepa-
rator)
Turn filter counterclockwise. Remove filter.
!
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while drain-
ing fuel tank.
5
6
7
Petcock
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clock-
wise. Bleed air from fuel system according
to engine manual.
Secondary Fuel Filter
Fuel Tank Sludge Drain Valve
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
Inspect fuel line, and replace if cracked or
worn.
OM-4428 Page 48
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9-8. Overload Protection (Deutz F4L2011-Powered Units)
!
Stop engine.
.
W
h
e
n
a
s
u
p
p
l
e
m
e
n
t
a
r
y
p
r
o
t
e
c
t
o
r
,
circuit breaker or fuse opens, it usu-
ally indicates a more serious prob-
lem exists. Contact Factory Autho-
rized Service Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter
winding from overload. If F1 opens,
weld and generator power is low or
stops entirely. If F2 opens, weld output
is low or stops entirely. 4 kVA/kW gener-
ator power is still available.
2
1
3
4
Circuit Breaker CB4 (Not Shown)
Supplementary Protector CB5
(CC/CV Models Only)
5
Supplementary Protector CB6
(CC/CV Models Only)
6
7
8
9
Circuit Breaker CB10 (Not Shown)
Supplementary Protector CB11
Supplementary Protector CB12
Supplementary Protector CB13
9
8
7
10 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may
stick to the workpiece more frequently
during low voltage (short arc length)
conditions. CB4 automatically resets
when the fault is corrected.
CB5 protects the 24 volt ac output to re-
mote receptacle RC14, and 24 volt out-
put to field current regulator board PC1
(CC/CV models only). If CB5 opens,
weld output and 24 volt output to RC14
stops. On units with optional three-
phase generator, generator power out-
put at receptacle RC5 also stops if CB5
opens.
5
4
CB6 protects the 115 volt ac output to
remote receptacle RC14 (CC/CV mod-
els only). If CB6 opens, 115 volt output
to RC14 stops.
CB10 protects the engine battery cir-
cuit. If CB10 opens, the engine will not
crank. CB10 automatically resets when
the fault is corrected.
CB11 protects the weld control circuit.
On CC models, if CB11 opens the max
OCV circuit does not work and open cir-
cuit voltage is variable at all times (see
max OCV note under Weld Controls in
els, weld output stops (generator power
is still available).
CB12 protects the field flashing circuit.
If CB12 opens, the generator may not
excite at start-up and weld and genera-
tor power output may not be available.
CB13 protects the engine control cir-
cuit. If CB13 opens, the engine does not
crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14
opens, the engine does not run at idle
speed. CB14 automatically resets when
the fault is corrected.
Press button to reset supplementary
protector.
Ref. 803 657
OM-4428 Page 49
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10-2. Routine Maintenance (Deutz F3L912-Powered Units)
Stop engine before maintaining.
. See Engine Manual and Maintenance Label
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
Recycle engine
fluids.
n
=
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Reference
* To be done by Factory Authorized Service Agent
Every
8
Hours
FUEL
WATER
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/
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~
O
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,
F
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p
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s
Every
50
Hours
~
W
e
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d
T
e
r
m
i
n
a
l
s
Every
100
Hours
Section
~
B
a
t
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e
r
y
T
e
r
m
i
n
a
l
s
n
A
i
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n
A
i
r
C
l
e
a
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e
r
E
l
e
m
e
n
t
Every
250
Hours
Engine
Manual,
Section
1/2 in.
(13 mm)
l
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b
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a
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S
y
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S
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A
r
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e
s
t
o
r
Every
500
Hours
n
l
W
e
l
d
C
a
b
l
e
s
Z
O
i
l
Z
O
i
l
F
i
l
t
e
r
Every
1000
Hours
10-3 and
Engine
FUEL
OR
Manual
SLUDGE
n
n
~
S
l
i
p
R
i
n
g
s
*
~
I
n
s
i
d
e
U
n
i
t
Z
F
u
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l
F
i
l
t
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r
~
D
r
a
i
n
S
l
u
d
g
e
l
Brushes*
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
Every
3000
Hours
~
I
n
j
e
c
t
o
r
s
*
Every
6000
Hours
or 5
Years
n
l
E
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g
i
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T
i
m
i
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g
B
e
l
t
OM-4428 Page 51
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10-3. Checking Generator Brushes
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
materialis at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
OM-4428 Page 52
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10-4. Servicing Air Cleaner (Deutz F3L912-Powered Units)
!
Stop engine.
NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damagecaused by using a damaged ele-
ment is not covered by the warranty.
1
3
4
2
. The air cleaner primary element can
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
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.
1
2
3
4
5
Housing
Keep nozzle
2 in (51 mm)
from element.
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
NOTICE − Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-4428 Page 53
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10-5. Inspecting/Cleaning Optional Spark Arrestor (Deutz F3L912-Powered Units)
!
1
Stop engine and let cool.
Spark Arrestor Muffler
Cleanout Plug
2
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
2
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 215 664
OM-4428 Page 54
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10-6. Adjusting Engine Speed (Deutz F3L912-Powered Units)
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 speed.
If necessary, adjust speed as fol-
lows:
Engine Speed
RPM (Hz)
(No Load)
1850
Weld/Power
(61.6 Hz)
1
2
Speed Adjustment Screw
Locknut
Loosen nut. Start engine.
Turn screw until engine runs at
weld/powerspeed. Tighten locknut.
.
D
o
n
o
t
s
e
t
e
n
g
i
n
e
s
p
e
e
d
h
i
g
h
e
r
than specified.
!
Stop engine.
Close side door.
2
1
Tools Needed:
9/16, 7/8 in
803 658 / 134 730-C
10-7. Servicing Optional Ether Starting Aid (Deutz F3L912-Powered Units)
!
Stop engine.
Improper handling or expo-
sure to ether can harm your
health. Follow manufactur-
er’s safety instructions on
cylinder.
If engine does not start in cold
weather, check ether cylinder as
follows:
Remove cylinder from valve.
1
2
3
Ether Cylinder
Valve
1
Scale
Weigh cylinder to see if it is empty.
Be sure atomizer is not plugged and
valve fitting is clean.
Replace cylinder according to
3
33 oz
(935 g)
15 oz
(425 g)
Full
Empty
2
ether2 7/96 − ST-153 382-A / Ref. 202 705 / S-0692
OM-4428 Page 55
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10-8. Servicing Fuel And Lubrication Systems (Deutz F3L912-Powered Units)
Tools Needed:
6
3
4
5
2
1
7
803 658
maintenance label for oil/filter change in-
formation.
To replace secondary fuel filter:
See engine manual.
Close doors.
!
Stop engine and let cool.
After servicing, start engine and
check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.
To drain water from fuel system:
To drain sludge from fuel tank:
Open primary fuel filter petcock and drain
water into metal container. Close petcock
when water-free fuel flows.
Beware of fire. Do not smoke and
keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.
1
2
3
4
Oil Filter
Oil Drain Valve And Hose
Oil Fill Cap
To replace primary fuel filter:
Primary Fuel Filter (Fuel/Water Sepa-
rator)
Turn filter counterclockwise. Remove filter.
!
Properly lift unit and secure in a level
position. Use adequate blocks or
stands to support unit while drain-
ing fuel tank.
5
6
7
Petcock
Apply thin coat of fuel to gasket on new filter.
Fill filter with fuel. Install filter and turn clock-
wise. Bleed air from fuel system according
to engine manual.
Secondary Fuel Filter
Fuel Tank Sludge Drain Valve
Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.
To change oil and filter:
Route oil drain hose and valve through hole
in base. See engine manual and engine
Inspect fuel line, and replace if cracked or
worn.
OM-4428 Page 56
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10-9. Overload Protection (Deutz F3L912-Powered Units)
Stop engine.
.
W
h
e
n
a
s
u
p
p
l
e
m
e
n
t
a
r
y
p
r
o
t
e
c
t
o
r
,
c
i
r
-
cuit breaker or fuse opens, it usually in-
dicates a more serious problem exists.
Contact Factory Authorized Service
Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter winding
from overload. If F1 opens, weld and gener-
ator power is low or stops entirely. If F2
opens, weld output is low or stops entirely.
4 kVA/kW generator power is still available.
3
4
Circuit Breaker CB4 (Not Shown)
2
1
Supplementary Protector CB5
(CC/CV Models Only)
5
Supplementary Protector CB6
(CC/CV Models Only)
6
7
8
9
Circuit Breaker CB10 (Not Shown)
Supplementary Protector CB11
Supplementary Protector CB12
Supplementary Protector CB13
9
8
7
10 Circuit Breaker CB14
(Not Shown)
CB4 protects the welding arc drive (dig) cir-
cuit. If CB4 opens, electrode may stick to
the workpiece more frequently during low
voltage (short arc length) conditions. CB4
automatically resets when the fault is cor-
rected.
CB5 protects the 24 volt ac output to remote
receptacle RC14, and 24 volt output to field
current regulator board PC1 (CC/CV mod-
els only). If CB5 opens, weld output and 24
volt output to RC14 stops. On units with op-
tional three-phase generator, power output
at receptacle RC5 also stops if CB5 opens.
4
5
CB6 protects the 115 volt ac output to re-
mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to RC14
stops.
CB10 protects the engine battery circuit. If
CB10 opens, the engine will not crank.
CB10 automatically resets when the fault is
corrected.
CB11 protects the weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit volt-
age is variable at all times (see max OCV
CB11 opens on CC/CV models, weld output
stops (generator power is still available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not excite
at start-up and weld and generator power
output may not be available.
CB13 protects the engine control circuit. If
CB13 opens, the engine does not crank.
CB14 protects fuel solenoid FS1. If CB14
opens, the engine does not start. CB14 au-
tomatically resets when the fault is cor-
rected.
Press button to reset supplementary pro-
tector.
Ref. 803 658
OM-4428 Page 57
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SECTION 11 − TROUBLESHOOTING
11-1. Troubleshooting
A. Welding − CC Models
Trouble
Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional Polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
check integrated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and weld excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 (see Sec-
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Check and tighten connections inside and outside unit.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Erratic weld output.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
Check engine speed, and adjust if necessary.
High weld output.
Low weld output.
Have Factory Authorized Service Agent check OCV control circuit.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
frequently during low voltage (short arc or10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions.
SR5.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in Remote position.
check control relay CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
OM-4428 Page 58
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B. Welding − CC/CV Models
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
nected to RC14.
Have Factory Authorized Service Agent check connector board PC6 and connections.
check brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Check and tighten connections inside and outside unit.
Erratic weld output.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
High weld output.
Check engine speed, and adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feed-
back circuit.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and adjust if necessary.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8
frequently during low voltage (short arc or10-9). Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and
length) conditions.
SR5.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Check position of Process/Contactor switch.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Repair or replace remote control device.
Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.
Constant speed wire feeder does not Reset supplementary protector CB5 or CB6 (see Section 9-8 or 10-9).
work.
Repair or replace wire feeder.
OM-4428 Page 59
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Trouble
Remedy
Low CV weld output.
Set Ampere Range switch to highest range.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current
regulator board PC1.
C. Standard Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle supplementary protectors.
tacles; weld output okay.
Reset GFCI receptacle.
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
Check fuses F1 and F2, and replace if open (see Section 9-8 or 10-9). Have Factory Authorized Service
Agent check integrated rectifier SR1, capacitor C9, and the rotor.
Reset supplementary protector CB12. Have Factory Authorized Service Agent check diode D1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Check engine speed, and adjust if necessary.
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine speed, and adjust if necessary.
tacles.
check integrated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Three-Phase Generator Power (CC/CV Models Only)
Trouble
Remedy
No or low output at optional three-
phase generator/receptacle RC5.
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional three-phase
generator/receptacle RC5.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage
feedback circuit.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacleRC5.
PC1.
OM-4428 Page 60
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E. Engine
Trouble
Remedy
Engine will not crank.
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8
or 10-9). Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check control relay CR1, control relay CR5, time delay relay
TD1, and Engine Control switch S1.
Engine cranks but does not start.
Check fuel level.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.
Air in fuel system. See engine manual.
Engine starts, but stops after 30 sec- Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
onds.
temperatureis too high (see Section 5-8). Automatic shutdown system is inhibited for 30 seconds after
start-up.
Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.
Engine hard to start in cold weather.
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperatureis too high (see Section 5-8). Automatic shutdown system is inhibited for 30 seconds after
start-up.
See engine manual.
Check fuel level.
Engine slowly stopped and cannot be
restarted.
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
Engine idles, but does not come up to
weld speed (models with idle option
only).
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(models with idle option only).
CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch Required-
TIG.
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
wetstacking occurs.
OM-4428 Page 61
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215 221-E
OM-4428 Page 63
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Figure 12-2. Circuit Diagram For CC Welding Generator (Deutz F4L2011-Powered Units) (Export Models)
OM-4428 Page 64
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235 275-A
OM-4428 Page 65
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Figure 12-3. Circuit Diagram For CC/CV Welding Generator (Deutz F4L2011-Powered Units)
OM-4428 Page 66
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215 806-E
OM-4428 Page 67
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Figure 12-4. Circuit Diagram For CC/CV Welding Generator
(Deutz F4L2011-Powered Units) (Export Models)
OM-4428 Page 68
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235 276-A
OM-4428 Page 69
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Figure 12-5. Circuit Diagram For CC Welding Generator (Deutz F3L912-Powered Units)
OM-4428 Page 70
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215 807-D
OM-4428 Page 71
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Figure 12-6. Circuit Diagram For CC/CV Welding Generator (Deutz F3L912-Powered Units)
OM-4428 Page 72
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215 808-D
OM-4428 Page 73
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SECTION 13 − RUN-IN PROCEDURE
run_in1 2007−04
13-1. Wetstacking
NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.
1
Welding Generator
2
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
NOTICE− Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.
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-4428 Page 74
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13-2. Run-In Procedure Using Load Bank
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
4
NOTICE− 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 name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generatoris loaded properly.
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
4
Engine Exhaust Pipe
Repeat procedure if wetstacking
is present.
S-0683
OM-4428 Page 75
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13-3. Run-In Procedure Using Resistance Grid
Stop engine.
Do not touch hot exhaust pipe,
engine parts, or load bank/grid.
Keep exhaust and pipe away
from flammables.
6
NOTICE− 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 ad-
just generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
4
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
+
NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Stop engine and let cool.
6
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-4428 Page 76
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SECTION 14 − GENERATOR POWER GUIDELINES
. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
14-1. Selecting Equipment
1
2
3
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
. Be sure equipment has double
insulated symbol and/or word-
ing on it.
1
2
!
Do not use 2-prong plug un-
less equipment is double in-
sulated.
3
OR
gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577
14-2. Grounding Generator To Truck Or Trailer Frame
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
Also see AWS Safety
&
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
2
3
EquipmentGrounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
2
GND/PE
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
. Electrically bond generator
frame to vehicle frame by met-
al-to-metal contact.
3
!
Bed liners, shipping skids,
and some running gear insu-
late the welding generator
from the vehicle frame. Al-
ways connect a ground wire
from the generator equip-
ment grounding terminal to
bare metal on the vehicle
frame as shown.
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
S-0854
OM-4428 Page 77
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14-3. 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
.
U
s
e
g
r
o
u
n
d
d
e
v
i
c
e
a
s
s
t
a
t
e
d
i
n
electrical codes.
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Also see AWS Safety
&
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
2
3
ST-800 576-B
14-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
Non-Resistive Load
3
VOLTS 115
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
2
AMPS 4.5
Hz
60
1
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
3
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-4428 Page 78
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14-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
Fan Duty
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
550
650
800
1100
14-6. 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-4428 Page 79
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14-7. 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-4428 Page 80
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14-8. Power Required To Start Motor
Single-PhaseInduction 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
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
1
3
AC MOTOR
2
Motor Voltage
VOLTS 230
AMPS 2.5
To find starting amperage:
CODE
HP
M
Hz
60
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
1/4
PHASE 1
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amper-
age required for a 230 V, 1/4 HP mo-
tor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
14-9. 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-4428 Page 81
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14-10. Typical Connections To Supply Standby Power
!
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
4
1
2
3
Fused
Disconnect
Switch
Properly install and ground
this equipment according to
its Owner’s Manual and na-
tional, state, and local codes.
Welding
Generator
Output
Utility
Electrical
Service
Transfer Switch
(If Required)
. Customer-supplied equipment
is required if generator will sup-
ply standby power during
emergencies or power out-
ages.
5
1 Utility Electrical Service
Essential
Loads
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is re-
stored.
Install correct switch (customer-
supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customer-
supplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wir-
ing must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt-
age and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the prem-
ises. If generator does not produce
enough output to meet all require-
ments, connect only essential
loads (pumps, freezers, heaters,
OM-4428 Page 82
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14-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
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
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-4428 Page 83
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SECTION 15 − PARTS LIST
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
n
o
t
available unless listed.
.
A
D
e
u
t
z
F
4
L
2
0
1
1
e
n
g
i
n
e
-
p
o
w
-
ered unit is shown below. See
insert for parts specific to a
Deutz F3L912-powered unit.
Parts not related to the engines
are the same in both units.
15
14
3
16
17
2
13
1
12
18
4
11
19
5 6
9
10
8
7
107
106
12
21
100 (Fig. 15-7)
20
99
92
101
22
90
125
98 (FIG. 15-2 OR 15-3)
105
95 (CC ONLY)
96
91
97 (CC ONLY)
93
103
102
94 (CC ONLY)
104 (FIG. 15-4 OR 15-5)
CC CC Models Only
CV CC/CV Models Only
Figure 15-1. Main Assembly
OM-4428 Page 84
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.
A
D
e
u
t
z
F
4
L
2
0
1
1
e
n
-
Deutz F3L912 Engine
gine-powered unit is
shown below. See in-
sert for parts specific to
a Deutz F3L912-pow-
ered unit. Parts not re-
lated to the engines are
the same in both units.
29
119
122
2
124
120
33
117
110
108
118
53
54
114
123
113
60
63
121
115
65
56
61
62
116
111
109
112
57
58
67
59
16 68
17
69
29
47
35 (Fig. 15−6)
70
44
45
25
46
28
27
31
24
26
48
23
43
50
51
33
2
42
126
49
30
34
41
32
40
52
39
38
37
36
2
67
68
2
2
53
54
55
69
35 (Fig. 15-6)
60
63
61
70
72
74
56
62
57
59
65
64
73
71
58
84
85
81
75
76
86
82
83
80
66
87
79
88
89
77
78
803 659 / 803 665
90
OM-4428 Page 85
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 15-1. Main Assembly
Quantity
. . . 1 . . . . . . . . . . . . . 189 824 . . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . ♦199 294 . . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 8
. . . 3 . . . . . . . . . . . . +189 828 . . PANEL, engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦212 570 . . Baffle, engine side (export models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . . 189 395 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . Z1 . . . ♦201 520 . . REACTOR, ac environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 1T . . . . 038 621 . . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 038 620 . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . . . . 081 499 . . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 206 352 . . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 203 260 . . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . SR4, SR5 . 215 909 . . RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . CB4 . . . 045 061 . . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 201 697 . . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . 201 613 . . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . ♦205 636 . . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 13 . . . . . . . . . . . . . 189 708 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 191 307 . . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 191 829 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 189 763 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 938 . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *♦192 939 . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 189 464 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 201 658 . . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . ♦+203 382 . . BASE e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . +201 934 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . ♦+202 640 . . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 189 052 . . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 190 198 . . CAP, tank screw-on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 192 041 . . LABEL, use diesel fuel only (Wordless Label) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . 222 513 . . LABEL, warning falling equipment can cause serious . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 224 265 . . LABEL, warning hot exhaust parts do not touch . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 201 592 . . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 201 851 . . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 202 633 . . SUPPORT, cover e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia u pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 200 730 . . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . Figure 15-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 191 577 . . GUARD, starter (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 191 809 . . BRACKET, mtg engine LH (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . 190 951 . . EDGE TRIM, styel tl750-b2 x 1/16 black w/clips 1.625 . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 191 817 . . BAFFLE, air (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 213 877 . . ENGINE, Deutz dsl elec F4L2011 (consisting of) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *067 265 . . . . FILTER, oil (engine) (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 744 . . . . FILTER, fuel spin-on (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *066 217 . . . . FILTER, fuel secondary (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 745 . . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *195 746 . . . . SENDER, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4428 Page 86
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Figure 15-1. Main Assembly (Continued)
. . . . . . . . . . . . . . . . . ♦174 064 . . IDLE, solenoid assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . ♦175 937 . . BRACKET, support solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . *067 266 . . BELT, blower (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . 201 714 . . BOX, air intake (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 201 748 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . ♦202 638 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . 202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . +215 252 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . 199 849 . . SCREW, 625-11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4
. . . 55 . . . . . . . . . . . . . 191 812 . . BRACKET, mtg engine RH (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 57 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 58 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4
. . . 59 . . . . . . . . . . . . . 135 205 . . NUT, 625-11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 199 507 . . HOSE, oil drain assy 20 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8-18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 2ft
. . . 63 . . . . . . . . . . . . . 176 528 . . FITTING, hose brs barbed elbow fem 1/2 tbg x 1/2 NPT . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . 173 336 . . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . 219 229 . . BRACKET, mtg solenoid (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . 206 297 . . BASE, fuel filter assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . 145 282 . . FITTING, hose brs barbed elbow M 5/16tbg x 1/4NPT . . . . . . . . . . . . . . . . 2
. . . 69 . . . . . . . . . . . . . 196 465 . . HOSE, SAE .312 ID X .560 OD X 23.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 200 032 . . HOSE, SAE .312 ID X .560 OD X 38.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 72 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e-coat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . 215 233 . . LABEL, diesel engine maintenance Deutz (Wordless Label) . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 75 . . . . . . . . . . . . +210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 76 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 77 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 78 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 78 . . . . . . . . . . . . . 199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . 199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 81 . . . . . . . . . . . . . 218 087 . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 82 . . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 83 . . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1
OM-4428 Page 87
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Item
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Dia.
Mkgs.
Part
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Quantity
Figure 15-1. Main Assembly (Continued)
. . . 88 . . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . 191 446 . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . . 6ft
. . . 91 . . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 92 . . . . . . . . . . . . . 218 086 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 93 . . . . . . . . . . . . . 224 266 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 94 . . . . . . . . . . . . . 190 179 . . PANEL, mtg components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . R4 . . . CC191 292 . . RESISTOR, WW fxd 375W 50 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 96 . . . . . R2 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . R3 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . Figure 15-2, Figure 15-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . Figure 15-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 233 953 . . LABEL, warning general precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 104 . . . . . Figure 15-4, Figure 15-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 105 . . . . . . . . . . . ♦202130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C
. . 106 . . . . . . . . . . . V193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C
. . 107 . . . PC1 . . V207 397 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250-20 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312-18 u-nut multi-thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 215 631 . . KIT, label (includes safety & informational labels) (CC models) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 632 . . KIT, label (includes safety & informational labels) (CC/CV models) . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 995 . . KIT, label (includes safety & informational labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 994 . . KIT, label (includes safety & informational labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F4L2011 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 991 . . KIT, label (includes safety & informational labels) (CC export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 990 . . KIT, label (includes safety & informational labels) (CC/CV export models)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 108 . . . . . . . . . . . . 199 063 . . ENGINE, Deutz dsl elec F3L912 d0392−166/00 . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . . *064 677 . . FILTER, oil (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . . *066 271 . . BELT, blower (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . *195 745 . . SWITCH, pressure oil 1.5 bar nc cont . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . *195 746 . . SENDER, coolant temp & 130 degee C switch . . . . . . . . . . . . . . . . . . . . . . 1
. . 113 . . . . . . . . . . . . 194 135 . . BACKPLATE, Deutz F3L912 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . . . . . . . . 194 572 . . SUPPORT, front engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . FS1 . . . 141 346 . . SHUTDOWN KIT, engine (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . . . . . . . . . . 118 452 . . FTG, adapter oil drain (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . . . . 193 313 . . MANIFOLD, exhaust muffler (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . 1
. . 118 . . . . . . . . . . . . 194 496 . . BAFFLE, lower air outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . 1
. . 119 . . . . . . . . . . . . 194 497 . . BAFFLE, upper air outlet (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . 194 500 . . BAFFLE, air intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . 194 485 . . HOSE, air cleaner (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . +201 714 . . BOX, air intake (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . . . 195 560 . . GUARD, starter hole (Deutz F3L912 engine) . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . 194 467 . . WASHER, flat 6.25idx11.50odx.062t buna n . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . . . . . . . . 212 944 . . LABEL, stick overlap weld ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 126 . . . . . . . . . . . . 233 088 . . LABEL, danger using a generator indoors can kill you in minutes (unit) . 1
+
*
When ordering a component originally displaying a precautionary label, the label should also be ordered.
C
C
Recommended Spare Parts.
♦optional
C CC models only.
C/CV models only.
V
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
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803 660-C
Figure 15-2. Control Box Assembly − CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 054 . . HARNESS, control box, weld control (consisting of) . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR7 . . . 188 636 . . . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . SR1, SR2 . 035 704 . . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CR5 . . . 223 710 . . . . RELAY, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH, tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011 622 . . . . SWITCH, tgl 3pdt 15a 125vac on−none−on spd term
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-4) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 092 670 . . . . CONN, rect univ 084 3p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 CB11, 12, 13 139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . 3
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . . . . . . . . . . . 215 013 . . HARNESS, unit weld control (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 158 465 . . . . CONN, rect univ 084 12p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONN, rect univ 084 4p/s 1row plug cable lkg . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 309 . . . . CLIP, snap in .630 bundle .250 hole .248 thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . R6 . . . . 141 424 . . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . CR6 . . ♦090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . CR3 . . . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 660 . . HARNESS, engine control (Deutz F4L2011 engine) (consisting of) . . . . 1
. . . 19 . . . D1/C1 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . CR1 . . . 214 876 . . . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CB14 . . ♦205 927 . . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 205 931 . . HARNESS, engine control (Deutz F3L912 engine) (consisting of) . . . . . 1
. . . 19 . . . D8/C8 . . 189 701 . . . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . CB10 . . . 190 374 . . . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . 21 . . . . CR1 . . . 214 876 . . . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . CB14 . . . 205 927 . . . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . CR8 . . ♦197 325 . . RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . TD1 . . . 214 928 . . TIMER, delay on make/break open 30 sec 12vdc . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . CR9 . . . 090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 235 251 . . HARNESS, fuel shutdown solenoid (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . R7 . . . . 235 250 . . . . RESISTOR, hsc 30 w 3 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 90
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24
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8
9
25
2
10
1
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12
13
14
23
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15
22
17
18
19
20
21
803 661-C
Figure 15-3. Control Box Assembly − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . CR3 . . . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 1
. . . 6 . . . . CR8 . . ♦197 325 . . RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR1 . . . 214 876 . . RELAY, encl 6vdc spst 35a/14vdc 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . D8/C8 . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB14 . . . 205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB10 . . . 190 374 . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CR5 . . . 223 710 . . RELAY, encl 12vdc dpst−no 25a 6pin flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . SR1 . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . TD1 . . . 214 928 . . TIMER, delay on make/break open 30 sec 12vdc . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . D1/C1 . . 189 701 . . DIODE CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4428 Page 91
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 23 . CB11, 12, 13 139 266 . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . . 3
. . . 24 . . . . CR9 . . . 090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 377 . . HARNESS, control box, cv weld control (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . 047 483 . . . . CONNECTOR, rect univ 084 15P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC3 . . . 158 466 . . . . CONNECTOR, rect univ 084 12P/S 3 row rcpt cable/panel lkg . . . . . . . 1
. . . . . . . . . . RC1 . . . 135 133 . . . . CONNECTOR, rect univ 084 9P/S 3 row rcpt cable/panel lkg . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . 193 324 . . . . SWITCH, rotary 6 position gold contacts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011 609 . . . . SWITCH,tgl spdt 15a 125vac on−none−on spd term chr
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (located on front panel, see Figure 15-5) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 150 316 . . . . CONN, rect univ 039 6p/s 3row plug cable lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . 177 859 . . . . CONN, body 5 terminal (to engine control switch S1) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 183 . . . . CONN, rect cinch 18 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 196 602 . . . . PLUG, cavity 18,30 position cinch connector . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 196 603 . . . . SEAL, switch 6 position rotary .250 shaft . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 141 450 . . . . CONN, rect metrmate 10skt 1row plug cable lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 206 024 . . HARNESS, engine control (Deutz F4L2011 engine) (consisting of) . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 916 . . . . HOUSING, contact 10-pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 205 931 . . HARNESS, engine control (Deutz F3L912 engine) (consisting of) . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG4 . . . . 114 062 . . . . CONNECTOR, rect univ 084 15P/S 3 row plug cable lkg . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 185 655 . . . . SEAL, wire univ 15P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 235 251 . . HARNESS, fuel shutdown solenoid (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . R7 . . . . 235 250 . . . . RESISTOR, hsc 30 w 3 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 148 850 . . . . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 92
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4
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
3
5
2
6
1
7
8
9
10
11
42
41
40
12
13
14
38
39
37
36
15
32
16
30
35
34
17
31
33
29
18
28
19
21
20
22
27
26
23
803 662
25
24
Figure 15-4. Panel, Front w/Components − CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 215 663 . . PLATE SCREENED, ident control rating; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 215 014 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220544 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4428 Page 93
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S2 . . . ♦021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S1 . . . . 212 436 . . SWITCH, ignition 4 position w/handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . 201 083 . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac
(European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . ♦202 683 . . SUPPLEMENTARY PROTECTOR, man reset 2p 40a 240vac
(export models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201 083 . . SUPPLEMENTARY PROTECTOR, man reset 2p 20a 250vac . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . . 3
. . . 14 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201 053 . . HARNESS, generator power (European Receptacle) (consisting of) . . . . 1
. . . 13 . . . . CB2 . . ♦093 996 . . . . SUPPLEMENTARY PRO, man reset 1p 20a 250vac frict . . . . . . . . . . . 1
. . . 13 . . . . CB3 . . ♦139 266 . . . . SUPPLEMENTARY PROTECTOR, man reset 1p 15a 250vac . . . . . . . 1
. . . 14 . . . GFCI1 . ♦151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213 577 . . HARNESS, generator power (export models) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189 549 . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038 620 . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . ♦176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (European Receptacle) . . 1
. . . 15 . . . . RC1 . . ♦173 556 . . RECEPTACLE, str 2p3w 32a 130v flange mtg (export models) . . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models) . . . . . . . . 1
. . . . . . . . . . RC3 . . ♦173 555 . . RECEPTACLE, str 2p3w 16a 130v flange mtg (export models) . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 190 861 . . LABEL, warning, electric shock and moving parts etc . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . +215 347 . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215 045 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215 403 . . PANEL, gen pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+204 258 . . PANEL, gen pwr (110/220 volt receptacles) (export models) . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦220491 . . SWITCH, ac/polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4428 Page 94
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 35 . . . . . HM . . . . 210 424 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . TEMP . . 217 084 . . GAUGE, coolant temp 0− 300 deg f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . OIL . . . . 217 083 . . GAUGE, pressure oil 0−100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦194 403 . . ADAPTER, oil pressure sender (Deutz F4L2011) . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . V1 . . . ♦164 874 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . A1 . . . ♦164 873 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . 019 602 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap−in nyl .750 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4428 Page 95
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803 663
Figure 15-5. Panel, Front w/Components − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 215 664 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 215 014 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220544 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . . 208278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 558 . . HARNESS, range (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . 148 439 . . . . HOUSING, rect univ 084 4p/s 1 row rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts (included in control box harness,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . GUARD, circuit breaker (for S6 − not included w/harness) . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr (included in
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control box harness, see Figure 15-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . SUPPLEMENTARY PROTECTOR, Man Reset 1p 15a 250vac . . . . . . . . 1
. . . 11 . . . . CB6 . . . 083 432 . . SUPPLEMENTARY PRO, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S1 . . . . 212 436 . . SWITCH, ignition 4 position w/handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . 201 083 . . SUPPLEMENTARY PROTECTOR, Man Reset 2p 20a 250vac . . . . . . . 1
. . . 14 . . . . CB1 . . ♦202 683 . . SUPPLEMENTARY PROTECTOR, Man Reset 2p 40a 240vac . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . CB2, CB3 ♦201 083 . . SUPPLEMENTARY PROTECTOR, Man Reset 2p 20a 250vac . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 201 109 . . HARNESS, generator power (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, Man Reset 1p 20a 250vac Frict . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 147 632 . . . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦201 053 . . HARNESS, generator power (European Receptacle) (consisting of) . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . . . SUPPLEMENTARY PRO, Man Reset 1p 20a 250vac Frict . . . . . . . . . . 1
. . . . . . . . . . CB3 . . . 139 266 . . . . SUPPLEMENTARY PROTECTOR, Man Reset 1p 15a 250vac . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦213 577 . . HARNESS, generator power (export models) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦189 549 . . BLOCK, term assy standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . ♦038 620 . . LINK, jumper term block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (European Receptacle) . . 1
. . . 17 . . . . RC1 . . ♦173 556 . . RECEPTACLE, str 2p3w 32a 130v flange mtg (export models) . . . . . . . . 1
. . . . . . . . . . RC2 . . ♦176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models) . . . . . . . . 1
. . . . . . . . . . RC3 . . ♦173 555 . . RECEPTACLE, str 2p3w 16a 130v flange mtg (export models) . . . . . . . . 1
. . . 18 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦214 926 . . SUPPLEMENTARY PROTECTOR, Man Reset 3p 50a 250vac . . . . . . . 1
. . . 24 . . . . . . . . . . . . +215 347 . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+215 406 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+215 403 . . PANEL, gen pwr (European Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . ♦+204 258 . . PANEL, gen pwr (110/220 volt receptacles) (export models) . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦215 363 . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦214 927 . . BOOT, circuit breaker 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 29 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 190 861 . . LABEL, warning, electric shock and moving parts etc . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 209 056 . . COVER, receptacle 2.250 dia lexan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦220 491 . . SWITCH, ac/polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 36 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 39 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . HM . . . . 210 424 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . TEMP . . 217 084 . . GAUGE, coolant temp 0− 300 deg f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . OIL . . . . 217 083 . . GAUGE, pressure oil 0−100 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 194 403 . . ADAPTER, oil pressure sender (Deutz F4L2011) . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . A1 . . . ♦164 873 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . V1 . . . ♦164 874 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 207 . . HARNESS, unit weld control − CV (consisting of) . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114 063 . . . . CONNECTOR, rect univ 084 4p/s 1 row plug cable lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . 193 184 . . . . CONNECTOR, rect cinch 30 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . 147 992 . . . . CONNECTOR, rect univ 039 10p/s 2 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . 158 465 . . . . CONNECTOR, rect univ 084 12p/s 3 row plug cable . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 088 731 . . . . BUSHING, snap-in nyl .375 ID x .500 mtg hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 135 873 . . . . CLIP, conduit convoluted 1/2 in mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 187 654 . . . . SEAL, wire univ 12p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 120 304 . . BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 98
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802 404-C
Figure 15-6. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, 375-16 x 1.50hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . ♦213 448 . . STATOR, exciter/gen pwr (export models) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +208 287 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦209 220 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . . 212997 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 210 446 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 4
OM-4428 Page 99
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 15-6. Generator (Continued)
. . . 21 . . . . . . . . . . . . . 049 026 . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . . . . . . . . . 191 579 . . COVER, starter hole Perkins/Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 6
. . . 24 . . . . . . . . . . . . . 172 555 . . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . . . . 602 159 . . SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . 601 961 . . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 27 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . 139 341 . . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . *190 823 . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 30 . . . . . . . . . . . . . 208 469 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 31 . . . . . . . . . . . . . 189 142 . . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 602 242 . . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . 602 211 . . WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . 2
. . . 34 . . . . . . . . . . . . . 604 534 . . SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 190 259 . . HARNESS, brush (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . 168 071 . . . . CONNECTOR, (kit) rect univ 084 9P/S 3 row plug cable lkg . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 651 . . . . SEAL, wire univ 9P/S 3 row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-4428 Page 100
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4
.
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a
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d
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a
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e
i
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a
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not available unless listed.
3
2
1
5
6
7
8
9
802 279-A
Figure 15-7. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . . SR3 . . . 215 910 . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 188 137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 188 517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . 188 135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 134 201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . 215 755 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 188 136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . 188 493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 208 334 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 208 335 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4428 Page 101
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
Original main power rectifiers
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
*
*
*
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
*
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
*
*
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2007 Miller Electric Mfg. Co.2007−01
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