Hobart CONTRACTOR 3025 User guide

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OM-492 190 603H

May 2000

Processes

MIG (GMAW) and Pulsed MIG (GMAW-P) Welding

Flux Cored (FCAW) Welding

Stick (SMAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A) Cutting and Gouging

Descriptio n

Engine Driven Welding Generator

Contractor 3025

Visit our website at

www.HobartWelders.com

From Hobart to You

Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

This Owner’s Manual is designed to help you get the most out of your Hobart products. Please take time to read the Safety precautions. They will help you

protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Hobart you can count on years of reliable service with proper maintenance. And if for some reason the unit

Hobart is registered to the ISO 9001 Quality System Standard.

needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

Hobart Welders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Y our distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section

25249.5 et seq.)

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

CALIFORNIA Proposition 65

Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The following terms are used interchangeably throughout this manual: MIG = GMAW, Wire Welding TIG = GTA W Stick = SMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISA TION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers existant en relation avec le moteur 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbol Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Weld, Power, And Engine Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions, Weights, and Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Volt-Ampere Curves 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Engine Prestart Checks 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Adding C o o lant To Radiator 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Connecting The Battery 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Installing Exhaust Pipe 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting To Weld Output Terminals 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Selecting Weld Cable Sizes 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Remote 14 Receptacle RC5 Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – OPERATING WELDING GENERATOR 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls (See Section 5-2) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Controls (See Section 5-1) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Meter Functions 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Mode Switch Settings 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Lift-Arc TIG Procedure 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – OPERATING AUXILIAR Y EQUIPMENT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Auxiliary Power Receptacles And Circuit Breakers 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) 23. . . . . . . . . . .

6-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P) 23. . . . . .

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Maintenance Label 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Servicing Air Cleaner 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Servicing Optional Spark Arrestor 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Servicing Engine Lubrication, Fuel, And Cooling Systems 28. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Adjusting Engine Speed 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Overload Protection 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Voltmeter/Ammeter Help Displays 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 – ELECTRICAL DIAGRAMS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – RUN-IN PROCEDURE 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Wetstacking 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Run-In Procedure Using Load Bank 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Run-In Procedure Using Resistance Grid 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – AUXILIARY POWER GUIDELINES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – PARTS LIST 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

 Only qualified persons should install, operate, maintain, and

repair this unit.

 During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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 equipment is a hazard.

 Do not touch live electrical parts.  Wear dry, hole-free insulating gloves and body protection.  Insulate yourself from work and ground using dry insulating mats

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

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

there is a danger of falling.

 Use AC output ONLY if required for the welding process.  If AC output is required, use remote output control if present on

unit.

 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).

 Properly install and ground this equipment according to its

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

 Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first – double-check connections.

 Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

 Turn off all equipment when not in use.  Do not use worn, damaged, undersized, or poorly spliced cables.  Do not drape cables over your body.  If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 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.

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

 Wear a safety harness if working above floor level.  Keep all panels and covers securely in place.  Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 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.

SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly of f from t h e weld.

 Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

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

rial (wool and leather) and foot protection.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

 Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

 If ventilation is poor, use an approved air-supplied respirator.  Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.

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

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing 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

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-492 Page 1

WELDING can cause fire or explosion.

HOT PARTS can cause severe burns.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

 Protect yourself and others from flying sparks and hot metal.  Do not weld where flying sparks can strike flammable material.  Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.  Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 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).

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

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

 Do not use welder to thaw frozen pipes.  Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

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

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

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

from your person before doing any welding.

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

 Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use ap-

proved air-supplied respirator.

 Allow cooling period before maintaining.  Wear protective gloves and clothing when

working on a hot engine.

 Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.  Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

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

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.  Never drape a welding torch over a gas cylinder.  Never allow a welding electrode to touch any cylinder.  Never weld on a pressurized cylinder – explosion will result.  Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and associated parts in good condition.

 Turn face away from valve outlet when opening cylinder valve.  Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

1-3. Engine Hazards

FUEL can cause fire or explosion.

 Stop engine and let it cool of f before checking or

adding fuel.

 Do not add fuel while smoking or if unit is near

any sparks or open flames.

 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.

OM-492 Page 2

STEAM AND HOT COOLANT can burn.

 If possible, check coolant level when engine is

cold to avoid scalding.

 Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

 If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two statements.

 Wear safety glasses and gloves and put a rag over radiator cap.  Turn cap slightly and let pressure escape slowly before completely

removing cap.

MOVING PARTS can cause injury.

 Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards

closed and securely in place.

 Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint-

enance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative ( –) battery cable from battery.

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

parts.

 Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

 Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

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

components.

BATTERY EXPLOSION can BLIND.

 Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

 Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

 Do not allow tools to cause sparks when working on a battery.  Do not use welder to charge batteries or jump start vehicles.  Observe correct polarity (+ and –) on batteries.  Disconnect negative (–) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

 Do not tip battery.  Replace damaged battery.  Flush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

 Use equipment outside in open, well-ventilated

areas.

 If used in a closed area, vent engine exhaust

outside and away from any building air intakes.

ENGINE HEAT can cause fire.

 Do not locate unit on, over, or near combustible

surfaces or flammables.

 Keep exhaust and exhaust pipes way from

flammables.

EXHAUST SPARKS can cause fire.

 Do not let engine exhaust sparks cause fire.  Use approved engine exhaust spark arrestor in

required areas – see applicable codes.

1-4. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

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

extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

 Wear a face shield to protect eyes and face.  Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper face, hand, and body protection.

 Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

 Turn off or unplug equipment before starting or

stopping engine.

 Do not let low voltage and frequency caused by

low engine speed damage electric motors.

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

where applicable.

OVERUSE can cause OV E RHE ATING.

 Allow cooling period; follow rated duty cycle.  Reduce current or reduce duty cycle before

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

 Use tongue jack or blocks to support weight.  Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

 Use only genuine MILLER replacement parts.  Perform engine maintenance and service

according to this manual and the engine manual.

OM-492 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

 The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

 If notified by the FCC about interference, stop using the

equipment at once.

 Have the installation regularly checked and maintained.  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.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

 Be sure all equipment in the welding area is

electromagnetically compatible.

 To reduce possible interference, keep weld cables as short as

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according t o this manual.

 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.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic 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.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

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

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

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.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-492 Page 4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT

UTILISATION

rom _nd_fre 11/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

 Identifie un message de sécurité particulier.

 Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

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

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant e t 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 1-5. Veuillez lire et respecter toutes ces normes de sécurité.

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

doivent être confiés qu’à des personnes qualifiées.

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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les circuits

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.

 Ne jamais toucher les pièces électriques sous tension.  Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

 S’isoler de l a p i èce et de la terre au moyen de tapis ou d’autres moyens iso-

lants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

 Ne pas se servir de source électrique àcourant électrique dans les zones

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

 Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

 Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

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

à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

 Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer q ue

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 conducteur de

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

 Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

 Mettre l’appareil hors tension quand on ne l’utilise pas.  Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

 Ne pas enrouler les câbles autour du corps.  Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct – ne pas utiliser le connecteur de pièce ou le câble de retour.

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

une électrode provenant d’une autre machine.

internes de l’appareil sont également sous tension à ce

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

 Porter un harnais de sécurité quand on travaille en hauteur.  Maintenir solidement en place tous les panneaux et capots.  Fixer le c âble 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.

Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation.

 Couper l’alimentation du poste et décharger les condensateurs d’entrée

comme indiqué dans la Section Maintenance avant de toucher des composants.

LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage génère

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

 Porter u n casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

 Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

 Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

des rayons visibles et invisibles intenses (ultraviolets et

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

 Eloigner votre tête des fumées. Ne pas respirer les fumées.  À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

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

 Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

 Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

 T ravailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

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

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

OM-492 Page 5

LE SOUDAGE peut provoquer un incendie ou une explosion.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

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

chaud.

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

substances inflammables.

 Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

 Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des ouvertures.

 Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.  Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

 Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).

 Brancher l e c âble 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 provoquant des risques d’électrocution et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.  En cas de non utilisation, enlever la baguette d’électrode du porte-électro-

de ou couper le fil à la pointe de contact.

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

en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

 Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

leur éclatement. Des étincelles peuvent être projetées de

DES PARTICULES VOLANTES peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles ris- quent de projeter du laitier.

 Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

 Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

 Prévoir u n e p ériode de refroidissement avant d’effec-

tuer des travaux d’entretien.

 Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

 Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

 Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

 Porteurs d e stimulateur cardiaque, restez à distance.  Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

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

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser .

 Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.  Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

 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.

 Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.  Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

 Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les normes de sécurité.

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

 Ne pas faire le plein en fumant ou proche d’une sour-

ce d’étincelles ou d’une flamme nue.

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

expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.

OM-492 Page 6

 Toujours vérifier le niveau de liquide de refroidissement dans le vase

 Si le moteur est chaud et que le liquide doit être vérifié, opérer comme

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

 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brûlures.

 Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter de se brûler.

d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du moteur).

bouchon du radiateur.

d’enlever le bouchon.

DES ORGANES MOBILES peuvent provoquer des blessures.

 Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de

protection.

 Arrêter le moteur avant d’installer ou brancher l’appareil.  Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux d’entretien et de d épannage.

 Pour e m p êcher tout démarrage accidentel pendant les travaux d’entre-

tien, débrancher le câble négatif (–) de batterie de la borne.

 Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-

ganes mobiles.

 Remettre en place les panneaux ou les dipositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.

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

en route accidentelle du moteur.

 Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

 Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

 Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

 Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-

hicules de démarrage rapide.

 Observer la polarité correcte (+ et –) sur les batteries.  Débrancher l e c âble négatif (–) en premier lieu. Le rebrancher en dernier

lieu.

L’ACIDE DE LA BATTERIE peut provoquer des br ûlures dans les YEUX et sur la PEAU.

 Ne pas renverser la batterie.  Remplacer une batterie endommagée.  Rincer immédiatement les yeux et la peau à l’eau.

LES GAZ D’ÈCHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels.

 Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

 En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti- ments.

LA CHALEUR DU MOTEUR peut provoquer un incendie.

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

de surfaces inflammables.

 Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie.

 Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

 Utiliser uniquement un pare-étincelles approuvé –

voir codes en vigueur.

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage uniquement pour soulever

l’appareil lui-même ; sans chariot, de bouteilles de

gaz, remorque, ou autres accessoires.

 Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.



En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.

 Porter un écran facial pour protéger le visage et les

yeux.

 Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de pro-

tecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.

 Les étincelles risquent de causer un incendie – éloigner toute substance

inflammable.

LE SURCHAUFFEMENT peut endommager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

 Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

d’une tension et d’une fréquence trop faibles.

 Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter l e facteur de

marche nominal.

 Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

 Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

 Établir la connexion avec la barrette de terre avant de

manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

UNE REMORQUE QUI BASCULE peut entraîner des blessures.

 Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

 Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

 Utiliser seulement les pièces de rechange d’origine.  Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

OM-492 Page 7

LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences.

 Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio–navigation et de communication, les

services de sécurité et les ordinateurs.

 Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

 L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Effectuer régulièrement le contrôle et l’entretien de l’installation.  Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

1-5. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Weld- ing Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l ’American Welding Society , 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

 L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que les robots.

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

électromagnétiquement.

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

ge aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

 Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

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

ment à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil- tres de ligne ou la pose de protecteurs dans la zone de travail.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de s écurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFP A 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les ef fets, pour l ’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné 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 magnétiques et 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 souhaitable de réduire votre exposition aux champs électromagnéti- ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif. 2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

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

vous. 5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur , il est alors recommandé de respecter les consignes ci–dessus.

OM-492 Page 8

2-1. Symbol Definitions

SECTION 2 – DEFINITIONS

Stop Engine

Start Engine Panel/Local Temperature Fuel

Engine Oil On

Engine

MIG (GMAW),

Wire

Foot Control Manual Control

Positive Negative

Fast

(Run, Weld/Power)

Read Operator’s

Manual

Stick (SMAW) TIG (GTAW) Circuit Breaker

Fast/Slow (Run/Idle)

Check Valve

Clearance

Amperes

Touch Start

(GTAW)

Alternating Current

(AC)

Slow (Idle)

Battery (Engine)

Volts

Pulsed

Output

Time

Hours

Do not switch while

welding

Wire Feed

SECTION 3 – SPECIFICATIONS

3-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC

CV/DC

Rated

Welding

Output

300 A, 32 V ,

60% duty

Cycle

Maximum

Open-Circuit

Voltage

90 5 – 375 A 10 – 34 V

Remote 14

Receptacle

Electrode

Positive

Amperage

Range In CC Mode

Voltage Range In CV Mode

Power Rating

Single-Phase,

120/240 V AC,

Seconds

Work Connection Glow Plug

Electrode Negative High Temperature

Auxiliary

12 kV A/kW

100/50 A,

60 Hz

Fuel Capacity Engine

13 gal (49 L)

Tank

Protective Earth

(Ground)

Kubota DH905

Water-Cooled,

Three-Cylinder,

Four-Cycle, 26 HP

Diesel Engine

OM-492 Page 9

3-2. Dimensions, Weights, and Operating Angles

Dimensions

Height 36 in (914 mm)

Width 24 in (610 mm) Depth 59 in (1499 mm)

A 19-7/8 i n (505 mm) B 18 in (457 mm) C 1 in (25 mm) D 15-5/8 in (397 mm) E 26-3/8 i n (679 mm) F 58-3/4 i n (1492 mm) G 13/32 i n (10 mm) Dia.

Weight

925 lb (420 kg)

3-3. Duty Cycle And Overheating

Front Panel End

4 Holes

800 426

 Do not exceed tilt angles or engine could

be damaged or unit could tip.

 Do not move or operate unit where it could

tip.

20°

20° 20°

Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load without overheating.

If unit overheats, output stops, a Help message is displayed (see Section 7-8), and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding.

 Exceeding duty cycle can

damage unit and void warranty.

20°

Overheating

OM-492 Page 10

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

Minutes

A or V

Reduce Duty Cycle

sduty1 5/95 / 196 698

3-4. Volt-Ampere Curves

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

A. CC Mode

ARC CONTROL

B. CV Mode

178 652 / 178 653

OM-492 Page 11

SECTION 4 – INSTALLATION

4-1. Installing Welding Generator

Movement Airflow Clearance

 Do not lift unit from end.

18 in

(460 mm)

18 in

(460 mm)

Location

Grounding

18 in

(460 mm)

GND/PE

18 in

(460 mm)

18 in

(460 mm)

 Do not weld on base. Weld-

ing on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.

 Always ground generator

frame t o vehicle frame to prevent electric shock and static electricity hazards.

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-

protected extension cord.

Electrically bond generator frame to vehicle frame

by metal-to-metal contact.

install1 12/99 – Ref. 800 652 / Ref. 800 477-A / 158 936-A / S-0854

OM-492 Page 12

4-2. Engine Prestart Checks

Check radiator coolant lev-

el when fluid is low in re-

covery tank.

Full

1/2 in

(13 mm)

Full

Diesel

Capacity

w/Overflow Tank

6.4 qt (6 L)

Full

Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.

Engine stops if oil pressure is too low or engine temperature is too high.

 This unit has a low oil pressure shut-

down switch. However, some conditions 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.

Follow run-in procedure in engine manual. If unburned fuel and oil collect in exhaust pipe during run-in, see Section 9.

Fuel  Do not use gasoline. Gasoline will

damage engine.

Add fresh diesel fuel before starting engine the first time (see maintenance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow room for expansion.

Do not run out of fuel or air enters fuel system and causes starting problems. See engine manual to bleed air from fuel system.

Oil

After fueling, check oil with unit on level surface. If oil is not up to full mark on dipstick, add oil (see maintenance label).

 Engine may use oil and wetstacking

may occur during run-in period. Check oil several times daily during run-in.

Coolant

Check coolant level in recovery tank before starting unit the first time. Add coolant if coolant i s b e l o w b o t t o m o f r a d i a t o r f iller neck (see Section 4-3 for radiator filling instructions.

Check coolant in recovery tank daily . If coolant is below Full level, add coolant until coolant level in tank is between Full and Low levels. If recovery tank coolant level was low , also check coolant level in radiator (see Section 4-3).

Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. Do not use 100% antifreeze or severe damage will occur.

802 330

Keep radiator and air intake clean and free of dirt.

 Incorrect engine temperature can

damage engine. Do not run engine without a properly working thermostat and radiator cap.

 T o improve cold weather starting:

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

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

Use correct grade oil for cold weather.

OM-492 Page 13

4-3. Adding Coolant To Radiator

Capacity

w/Overflow Tank

6.4 qt (6 L)

Full

 Stop engine and let cool.

 Check coolant level according

to Section 4-2 before starting this procedure.

If coolant level is below bottom of radiator filler neck, add coolant as follows:

1 Radiator Air Bleed Screw Remove radiator air bleed screw.

Add coolant to radiator until coolant is at bottom of filler neck. This ensures all air is purged from the system.

Reinstall screw and radiator cap. Check coolant level in recovery tank (see Section 4-2).

Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. D o not use 100% antifreeze or severe damage will occur.

Tools Needed:

4-4. Connecting The Battery

 Connect

negative (–) cable last.

–

Ref. 802 330

OM-492 Page 14

Tools Needed:

3/8, 1/2 in

Ref. 189 438-A / 802 330 / Ref. S-0756-D

4-5. Installing Exhaust Pipe

 Point exhaust pipe in desired

direction. I f unit is truck or trailer mounted, point pipe away from direction of travel.

4-6. Connecting To Weld Output Terminals

Tools Needed:

1/2 in

802 173-B / Ref. 189 438-A

1 Positive (+) Weld Output

Terminal

2 Negative (–) Weld Output

Terminal

For MIG welding, connect work cable to Negative (–) terminal and wire fee d e r c a b l e t o P o s i t ive (+) terminal.

For Stick/TIG welding, connect work cable to Negative (–) terminal and electrode holder cable to Positive (+) terminal.

POSITIVE NEGATIVE

801 941-A / Ref. 189 438-A / 802 174-B

OM-492 Page 15

4-7. Selecting Weld Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Welding

Amperes

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your distributor for the mm2 equivalent weld cable sizes. S-0007-E

100 ft (30 m) Or Less

10 – 60%

Duty Cycle

60 – 100% Duty

Cycle

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

10 – 100% Duty Cycle

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

4-8. Remote 14 Receptacle RC5 Information

NOTE

Engine runs at weld/power speed whenever a device connected to the remote 14 receptacle is running.

Socket* Socket Information

24 VOLTS AC

115 VOLTS AC

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

A 24 volts ac. Protected by circuit breaker CB11. B Contact closure to A completes 24 volts ac

contactor control circuit.

I 115 volts ac. Protected by circuit breaker CB12.

J Contact closure to I completes 115 volts ac

contactor control circuit.

C Output to remote control; 0 to +10 volts dc, +10

volts dc in MIG mode. D Remote control circuit common. E 0 to +10 volts dc input command signal from

remote control.

M CC/CV select (CC/CV models).

F Current feedback; +1 volt dc per 100 amperes. H Voltage feedback; +1 volt dc per 10 output recep-

tacle volts.

*The remaining sockets are not used.

OM-492 Page 16

802 174-B

GND

G Circuit common for 24 a nd 115 volts ac circuits.

K Chassis common.

Notes

OM-492 Page 17

SECTION 5 – OPERATING WELDING GENERATOR

5-1. Controls (See Section 5-2)

56 8 9

OM-492 Page 18

Ref. 189 438-A / 802 330

5-2. Description Of Controls (See Section 5-1)

 The fan motor is thermostatically

controlled and only runs when cooling is needed.

Engine Lights

1 Battery Charging Light Light goes on if engine alternator is not charg-

ing battery. Engine continues to run.

 Stop engine and fix trouble if Battery

Charging light goes on.

2 Engine Temperature Light Light goes on and engine stops if engine tem-

perature is too high.

 Stop engine and fix trouble if Engine

Temperature light goes on.

3 Engine Oil Pressure Light Light goes on and engine stops if oil pressure

is too low. Light goes on momentarily during start-up but goes out when engine reaches normal oil pressure.

 Stop engine and fix trouble if Engine

Oil Pressure light stays on after startup.

4 Glow Plug Light Light goes on when glow plug is energized and

warming up. Glow plug warms in about six seconds and engine can be started (see starting instructions following).

 Do not use glow plug longer than 20

seconds.

Engine Gauges

5 Engine Hour Meter 6 Fuel Gauge

Weld Controls

7 Dig/Inductance Control Control adjusts Dig when Stick mode is se-

lected on mode switch. When control is set toward minimum, short-circuit amperage at low arc voltage is the same as normal welding amperage.

When set toward maximum, short-circuit am-

perage is increased at low arc voltage to assist with arc starts and help prevent the electrode from sticking while welding (see volt-ampere curves in Section 3-4).

Select setting best suited for application. Control adjusts inductance when MIG or

V-Sense Feeder position is selected on the mode switch. Inductance determines the “wetness” of the weld puddle. When set toward maximum, “wetness” (puddle fluidity) in- creases.

When Pulsed MIG or one of the TIG modes is selected, this control is not functional.

8 Voltmeter Meter displays weld voltage and help mes-

sages (see Sections 5-3 and 7-8). 9 Ammeter Meter displays weld amperage and help mes-

sages (see Sections 5-3 and 7-8). 10 V/A (Voltage/Amperage) Adjustment

Control 11 Mode Switch The Mode switch setting determines both the

process and output On/Off control (see Section 5-4). Source of control (panel or remote) for the amount of output is selected by the V/A Control switch.

For Air Carbon Arc (CAC-A) cutting and gouging, place switch in Stick position. For best results, place Inductance/Dig control in the maximum position.

12 V/A (Voltage/Amperage) Control Switch For front panel control, place switch in Panel

position and use the V/A Adjustment control. For remote control, make connections to Re-

mote 14 receptacle, and place switch in Remote position. In most modes, remote control is a percent of V/A Adjustment control setting (value selected on V/A Adjustment control is maximum available on remote). In the MIG mode, remote control provides full range of unit output regardless of V/A Adjust control setting.

Engine Starting Controls

13 Glow Plug Switch Use switch to energize glow plug for cold

weather starting. Glow plug warms in about six seconds and engine can be started (see starting instructions following).

14 Engine Control Switch Use switch to start engine, select speed, and

stop engine. In Run/Idle position, engine runs at idle speed at no load, and weld/power speed under load. In Run position, engine runs at weld/power speed.

 Place switch in Run position to operate

most GMAW equipment.

To Start: Above 325 F: turn Engine Control switch to

Start. Rel e a s e switch when engine starts and Engine Oil Pressure light goes out.

 If engine does not start, let engine come

to a complete stop before attempting restart.

Below 325 F: turn engine control switch to Run/Idle position. Push Glow Plug switch up and hold about six seconds. Turn Engine Control switch to Start. Release switch when engine starts and Engine Oil Pressure light goes out. Do not crank engine while engine is turning.

 If engine does not start, let engine come

to a complete stop before attempting restart.

To Stop: turn Engine Control switch to Off position.

 Push engine stop lever to stop engine if

Engine Control switch does not work (see item 15).

15 Engine Stop Lever Use lever to stop engine if Engine Control

switch does not work.

OM-492 Page 19

5-3. Meter Functions

NOTE

Mode Meter Reading At Idle Meter Reading While Welding

Scratch

Start TIG

Lift-Arc TIG

TIG

MIG

Pulsed

MIG

Stick

V-Sense

Feeder

The meters display the actual weld output values for approximately three seconds after the arc is broken.

80.0 85

Actual Volts (OCV) Preset Amps

7.0 85

Actual Volts Preset Amps

Blank Preset Amps

24.5

Preset Volts Blank

PPP PPP

Pulse Display Pulse Display

Blank Preset Amps

80.0 85

Actual Volts (OCV) Preset Amps

80.0

Flashes OCV And Preset Blank

10.3 85

Actual Volts Actual Amps

10.3 85

Actual Volts Actual Amps

10.3 85

Actual Volts Actual Amps

24.5 250

Actual Volts Actual Amps

24.5 250

Actual Volts Actual Amps

24.5 85

Actual Volts Actual Amps

24.5 85

Actual Volts Actual Amps

24.5 250

Actual Volts Actual Amps

5-4. Mode Switch Settings

NOTE

Mode Switch Setting Process Output On/Off Control

Scratch Start TIG GTAW Electrode Hot

Lift-Arc TIG GTAW – See Section 5-5 Electrode Hot

TIG GTAW With HF Unit, Pulsing Device, Or Remote Control At Remote 14

MIG GMAW At Remote 14

Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14

CC Stick (SMAW) With Remote On/Off At Remote 14

Stick SMAW Electrode Hot

V-Sense Feeder MIG (GMAW) With V oltage Sensing Wire Feeder Electrode Hot

OM-492 Page 20

The Stick and CC modes provide the Adaptive Hot Start feature, which automatically increases the output amperage at the start of a weld should the start require it. This eliminates electrode sticking at arc start.

5-5. Lift-Arc TIG Procedure

Do NOT Strike Like A Match!

Notes

“Touch”

1 – 2

Seconds

With Mode Switch in the Lift-Arc TIG position, start an arc as follows:

1 TIG Electrode 2 Workpiece Touch tungsten electrode to work-

piece at weld start point, hold

electrode to workpiece for 1-2 seconds, and slowly lift electrode.

An arc will form when electrode is lifted.

Normal open-circuit voltage is not present before tungsten electrode touches workpiece; only a low sensing voltage is present between electrode and workpiece. The solid-state output contactor does not energize until after electrode is touching workpiece. This allows electrode to touch workpiece without overheating, sticking, or getting contaminated.

Ref. S-156 279

OM-492 Page 21

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

6-1. Auxiliary Power Receptacles And Circuit Breakers

1 2 3 75 6 4

Weld

Current

In Amperes

350 300 250 200 150 100

 If unit does not have GFCI recep-

tacles, use GFCI-protected extension cord.

 Auxiliary power decreases as weld

current increases.

1 240 V 50 A AC Receptacle RC3 RC3 supplies 60 Hz single-phase power at

weld/power speed. Maximum output is 12 kVA/kW.

2 120 V 15 A AC Duplex Receptacle

RC2

3 120 V 15 A AC Duplex Receptacle

RC1

RC2 and RC1 supply 60 Hz single-phase power at weld/power speed. Maximum output from RC2 or RC3 is 1.8 kVA/kW.

SIMULTANEOUS WELDING AND AUXILIARY POWER

Three-Phase

Receptacle

–

Single-Phase

240 V

Receptacle

Amperes

–

5 15 30 35 40 45 50

Total

Power

In Watts

11900

9600 7500 5600 3900 2400

1100

4 240 V 30 A, AC Twistlock Receptacle

RC6

RC6 supplies 60 Hz three-phase power at weld/power speed. Maximum output is 12 kVA/kW.

5 Circuit Breakers CB3 And CB4 CB3 and CB4 protect RC1, RC2, and RC3

from overload. If CB3 opens, RC1 and RC3 do not work. 120 volts ac may still be present at RC3. If CB4 opens, RC2 and RC3 do not work. 120 volts ac may still be present at RC3. Press button to reset breaker.

6 Circuit Breakers CB1 And CB2 CB1 protects RC1 and CB2 protects RC2

from from overload. If CB1 or CB2 opens,

120 V

Receptacle

Amperes

16 38 40 40 40 40 40

240 V

Amperes

–

4 10 13 19 23 26 30

189 438-B

the receptacle does not work. Press button to reset breaker.

7 Circuit Breaker CB13 CB13 protects RC6 from overload. If CB13

opens, the receptacle does not work. Push breaker bar u p t o r e s e t .

 If a breaker continues to open, contact

Factory Authorized Service Agent.

Combined output of all receptacles limited to 12 kVA/kW rating of the generator.

EXAMPLE: I f 1 3 A i s drawn from RC1 and RC2, only 37 A is available at RC3:

2 x (120 V x 13 A) + (240 V x 28 A) = 12 kVA/kW

8 Auxiliary Power While Welding Table

OM-492 Page 22

6-2. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P)

120V

240V

120V

240V

Tools Needed:

The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram.

1 Plug Wired for 120/240 V ,

3-Wire Load

When wired for 120 V loads, each duplex receptacle shares a load with one half of 240 V receptacle.

2 Plug Wired for 240 V , 2-Wire

Load 3 Neutral (Silver) Terminal 4 Load 1 (Brass)Terminal 5 Load 2 (Brass) Terminal 6 Ground (Green) Terminal Strip cord jacket back enough to

separate conductors. Strip conductors enough to make

good contact with plug terminals. Make plug connections and reinstall outer shell and cord grip.

Tighten assembly screws onto shell. Do n o t o v ertighten.

Plug1 7/99 – ST-120 813-D

6-3. Wiring Instructions For Optional 240 Volt, 3-Phase Twistlock Plug (NEMA L15-30P)

240V

1 240 V AC Three-Phase, 30 A,

3P4W Twistlock Plug 2 Load 1 (Brass) Terminal (X) 3 Load 2 (Brass)Terminal (Y) 4 Load 3 (Brass) Terminal (Z) 5 Ground (Green) Terminal (G) 6 Outer Shell 7 Cord Grip Strip cord jacket back enough to sep-

arate conductors. Strip conductors enough to make

good contact with plug terminals. Make plug connections and reinstall outer shell and cord grip.

Tighten assembly screws onto shell. Do not overtighten.

Tools Needed:

Plug2 7/99 – 802 437

OM-492 Page 23

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING

7-1. Routine Maintenance

Note

Check fuel lines and connections. See Section 7-5.

Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.

 Stop engine before maintaining.

Recycle

engine

fluids.

 See also Engine Manual and Maintenance Label.

Service engine more often if used in severe conditions.

* To be done by Factory Authorized Service Agent.

8 h

Wipe Up

Spills.

RecoveryTank

Full

Check Fluid

Levels. See

Section 4-2.

FUEL

WATER

Drain Water From Fuel System. See

Section 7-5.

20 h

Check and clean optional spark arrestor screen. See Section 7-4.

50 h

Clean an d tighten weld terminals.

Service air filter element. See Section 7-3.

Clean and tighten battery connections.

Change oil. See Section 7-5 and maintenance label.

Check radiator hoses and clamps.

Replace unreadable labels.

100 h

Check air cleaner hoses for cracks and loose clamps.

Check belt tension.

200 h

Change oil filter. See Section 7-5 and maintenance label.

Replace primary fuel filter. See Section 7-5.

5/16 in. (8 mm)

OM-492 Page 24

400 h

Replace secondary fuel filter. See Section 7-5.

500 h

Drain sludge from

fuel

tank.

Blow out or vacuum inside. During heavy service, clean monthly.

Replace fuel lines and clamps. See Section 7-5.

Replace fan belt.

FUEL

SLUDGE

Flush radiator.

Repair or replace cracked cables.

800 h

Check valve clearance.*

1000 h

Service welding generator

brushes and slip rings. Service

more often in dirty conditions.*

2000 h

Replace radiator coolant and hoses

Notes

OM-492 Page 25

7-2. Maintenance Label

OM-492 Page 26

7-3. Servicing Air Cleaner

Blow

Inspect

 Stop engine.

 Do not run engine without air

cleaner or with dirty element.

1 Evacuator Valve 2 Dust Cap 3 Element 4 Housing Open ev a cuator valve weekly to re-

move dust. Clean or replace element if dirty or damaged. Replace element yearly or after six cleanings.

To Clean air filter:

Wipe off cap and housing. Remove cap and dump out dust. Wipe dust from inside cap and housing with damp cloth. Remove element and reinstall cap.

 Do not clean housing with air

hose.

Clean element with compressed air. Max. air pressure: 100 psi (690 kPa). Replace element if it has holes or damaged gaskets.

Reinstall element and cap

7-4. Servicing Optional Spark Arrestor

Ref. 189 438-A / 801 964

 Stop engine and let cool.

1 Spark Arrestor Screen Clean and inspect screen. Replace

spark arrestor if screen wires are broken or missing.

Tools Needed:

1/4 in

Ref. 189 438-B / 802 175-B

OM-492 Page 27

7-5. Servicing Engine Lubrication, Cooling, And Fuel Systems

FLOW

 Stop engine and let cool.

1 Oil Filter 2 Oil Drain Valve 3 1/2 ID x 12 in Hose 4 Fuel Line 5 Primary Fuel Filter 6 Secondary Fuel Filter 7 Petcock 8 Radiator Cap 9 Radiator Air Bleed Screw 10 Fuel Tank Sludge Drain

To change oil and filter:

Pull oil drain hose through access hole in base. Change engine oil and filter according to instructions in engine manual.

 Close valve and valve cap before ad-

ding oil and running engine.

Fill crankcase with new oil to full mark on dipstick (see Section 4-2).

To drain water from fuel system:

Open secondary fuel filter petcock and drain water into metal container. Close petcock when water-free fuel flows.

To change fuel filters:

Install new primary fuel filter as shown. Replace secondary fuel filter according to

engine manual. Replace fuel lines if cracked or worn. Wipe up any spilled fuel.

 After servicing, start engine and

check for fuel leaks. Stop engine, tighten connections as

necessary, and wipe up fuel.

Tools Needed:

9/16 in

Ref. 189 438-A / 802 173-A / S-0842

To change coolant:

Change coolant according to engine manual.

Run engine until engine reaches normal operating temperature. Loosen air bleed screw to remove air from cooling system. Tighten screw.

Check coolant level in recovery tank. Add coolant if necessary.

To drain sludge from fuel tank:

Put metal container under drain, and remove sludge drain plug. Reinstall plug when done.

OM-492 Page 28

7-6. Adjusting Engine Speed

2450 ± 100 rpm

3750 Max

After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows:

Start engine and run until warm. Turn V/A control to max.

Adjusting Idle Speed

Turn Engine Control switch to Run/ Idle position.

1 Throttle Solenoid 2 Idle Speed Jam Nut 3 Idle Speed Screw Loosen nut and turn screw clock-

wise to increase idle speed. Turn screw counterclockwise to decrease idle speed. Tighten nut.

See engine manual for governor sensitivity adjustment.

Adjusting Weld/Power Speed

4 Weld Speed Jam Nut 5 Adjustment Screw Turn Engine Control switch to Run

position. Loosen n ut an d tur n screw counterclockwise to increase speed. Turn screw clockwise to decrease speed. Tighten nut.

Using Engine Stop Lever

6 Engine Stop Lever Use lever to stop engine if Engine

Control switch does not work.

Tools Needed:

10 mm

802 330

OM-492 Page 29

7-7. Overload Protection

Tools Needed:

3/8 in

 Stop engine.

 When a circuit breaker opens,

it usually indicates a more serious problem exists. Contact Factory Authorized Service Agent.

1 Circuit Breaker CB12 CB12 protects the 115 volt ac out-

put to Remote 14 receptacle RC5. If CB12 opens, 1 15 volt ac output to RC5 stops.

2 Circuit Breaker CB11 CB11 protects the 24 volt ac output

to Remote 14 receptacle RC5. If CB11 opens, 24 volt ac output to RC5 stops.

Press button to reset breaker. 3 Circuit Breaker CB7 4 Circuit Breaker CB8 5 Circuit Breaker CB9 6 Circuit Breaker CB10

CB7 protects the engine glow plug from overload. If CB7 opens, the glow plug does not work and engine may not start in cold weather. Check continuity and connections of engine glow plug.

CB8 protects the engine wiring system from overload. If CB8 opens, the engine will not crank. Check battery, starter, and engine control switch.

CB9 protects the engine throttle solenoid from overload. If CB9 opens, the engine will not run at idle speed. Check throttle solenoid TS1 for obstructions.

CB10 protects the engine fuel solenoid from overload. If CB10 opens, the engine cranks but does not start. Check fuel solenoid FS1 for obstructions.

OM-492 Page 30

Ref. 189 438-B / 802 174-A / 802 175-B

7-8. Voltmeter/Ammeter Help Displays

HE.L P–0

HE.L P–1

HE.L P–2

HE.L P–3

HE.L P–5

HE.L P–6

HE.L P–7

HE.L P–8

Use the voltmeter/ammeter help displays to help determine the cause of no weld output. When a help display is shown, the inverter module weld output has stopped but the engine continues to run. Correct the problem before r esuming operation.

The display screen resets when the fault is corrected.

 All directions are in reference to the front

of the unit. All circuitry referred to is located inside the inverter module.

1 Help 0 Display Indicates a shorted thermistor R T2 on the left

side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

2 Help 1 Display Indicates a malfunction in the primary power

circuit possibly caused by applying a high weld load at idle speed. Turn Engine Control switch to Run position. If problem continues, contact a Factory Authorized Service Agent.

HE.L P–4

3 Help 2 Display

Indicates a malfunction in the thermal protection circuitry located on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

4 Help 3 Display

Indicates the left side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-3). Operation will continue when the unit has cooled.

5 Help 4 Display Indicates a malfunction in the thermal protec-

tion circuitry located on the right side of the unit. I f this display is shown, contact a Factory Authorized Service Agent.

6 Help 5 Display

Indicates the right side of the unit has overheated. The unit has shut down to allow the fan to cool it (see Section 3-3). Operation will continue when the unit has cooled.

HE.L P–9

802 174-B

7 Help 6 Display Indicates that the input voltage is too low and

the unit has automatically shut down. Operation will continue when the voltage is within the acceptable lower range limit (15% below the applicable input voltage). If this display is shown, have a Factory Authorized Service Agent check the power generator output voltage.

8 Help 7 Display Indicates that the input voltage is too high and

the unit has automatically shut down. Operation will continue when the voltage is within the acceptable upper range limit (15% above the applicable input voltage). If this display is shown, have a Factory Authorized Service Agent check the power generator output voltage.

9 Help 8 Display Indicates a malfunction in the secondary pow-

er circuit of the unit. If this display is shown, contact a Factory Authorized Service Agent.

10 Help 9 Display Indicates a shorted thermistor RT1 on the

right side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

OM-492 Page 31

7-9. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check control settings.

Check weld connections. Disconnect equipment from auxiliary power receptacles during start-up. Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-

necting board PC2, and control board PC1. If using remote control, be sure mode switch is in a position that provides output control at Remote 14

receptacle (see Sections 4-8 and 5-1). Check, repair, or replace remote control. Unit overheated. Allow unit to run so fan cools unit (see Section 3-3).

Ammeter and voltmeter do not work after unit has run out of fuel.

Low weld output. Check control settings.

High weld output. Check control settings.

Weld output cannot be adjusted. Check position of V/A Control switch (see Section 5-1).

Erratic weld output. Check control settings.

Restart the engine.

Place V/A Control switch in Panel position, or move switch to Remote position and connect remote amperage/voltage control to Remote 14 receptacle RC5 (see Section 4-8).

Check and clean air cleaner as necessary (see Section 7-3). Check engine speed, and adjust if necessary (see Section 7-6). If using remote control, be sure mode switch is in a position that provides output control at Remote 14

receptacle RC5 (see Sections 4-8 and 5-1). Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-

necting board PC2, and control board PC1. See engine manual.

Check engine speed, and adjust if necessary (see Section 7-6). Check for obstructed movement of throttle solenoid linkage. Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.

Have Factory Authorized Service Agent check voltage regulator board PC8 and control board PC1.

OM-492 Page 32

Clean and tighten connections both inside and outside unit. Check and secure lead connections to A/V control. Be sure connection to work piece is clean and tight. Remove excessive coils from weld cables. Use dry, properly stored electrodes. Check engine speed, and adjust if necessary (see Section 7-6). Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-

necting board PC2, and control board PC1.

Trouble Remedy

Remote contactor control does not activate contactor.

Check and tighten connections to Remote 14 receptacle RC5 (see Section 4-8).

Lack of high frequency; difficulty in establishing Gas Tungsten Arc Welding arc.

Wandering arc – poor control of arc direction.

Tungsten electrode oxidizing and not remaining bright after conclusion of weld.

No 115 volts ac output at Remote 14 receptacle RC5.

No 24 volts ac output at Remote 14 receptacle RC5.

Use proper size tungsten for welding amperage.

Reduce leakage of high frequency from torch or work cable (check grounding, remove excessive coils from weld cables, use shorter weld cables, etc.).

Check cables and torch for cracked or deteriorated insulation or bad connections. Repair or replace necessary parts.

Reduce gas flow rate.

Select proper size tungsten. Properly prepare tungsten. Shield weld zone from drafts.

Increase postflow time. Check and tighten all gas fittings. Properly prepare tungsten. Reset circuit breaker CB12 (see Section 7-7).

Reset circuit breaker CB11 (see Section 7-7).

B. Auxiliary Power

Trouble Remedy

No power output. Reset circuit breakers (see Section 6-1).

Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, interconnecting board PC2, and control board PC1.

Low power output. Check air cleaner, and clean or replace element if necessary.

Check engine speed, and adjust if necessary (see Section 7-6).

See engine manual. High power output. Check engine speed, and adjust if necessary (see Section 7-6). Erratic power output. Check receptacle wiring and connections.

Check governor according to engine manual.

Have Factory Authorized Service Agent check brushes, slip rings, voltage regulator board PC8, intercon-

necting board PC2, and control board PC1.

OM-492 Page 33

C. Engine

Trouble Remedy

Engine will not crank. Reset circuit breaker CB8 (see Section 7-7).

Check battery voltage.

Check battery connections and tighten if necessary.

Have Factory Authorized Service Agent check Engine Control switch S1. Engine cranks, but does not start. Check fuel level (see Section 4-2).

Open fuel valve (see Section 4-2).

Check oil level (see Section 4-2). Engine will not start if oil pressure is low.

Reset circuit breaker CB10 (see Section 7-7).

Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if coolant

temperature is high.

Use Glow Plug switch if unit does not start in cold weather. If unit still does not start, reset circuit

breaker CB7 (see Section 7-7).

Service primary and secondary fuel filters (see Section 7-5).

Check battery and replace if necessary.

Check engine charging system according to engine manual.

Bleed air from fuel system according to engine manual.

Have Factory Authorized Service Agent check low oil pressure switch S2, engine coolant tempera-

ture switch S3, and control relay CR1.

See engine manual. Engine starts but stops when Engine

Control switch returns to Run position.

Engine does not stop. Stop engine by pushing down engine stop lever (see Section 4-2) or closing fuel valve (see Section

Engine stopped during normal operation.

Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.

Check oil level (see Section 4-2). Engine will not start if oil pressure is too low.

Reset circuit breaker CB10 (see Section 7-7).

Check coolant level and fan belt (see Section 4-2 and engine manual). Engine will not start if engine

temperature is too high.

Check and refill crankcase with proper viscosity oil for operating temperature, if necessary (see en-

gine manual).

Have Factory Authorized Service Agent check low oil pressure switch S2 and engine coolant temper-

ature switch S3.

4-2). After stopping engine, adjust fuel solenoid linkage (see engine manual).

Check fuel level (see Section 4-2).

Open fuel valve (see Section 4-2).

Check oil level (see Section 4-2). Engine stops if oil pressure is too low.

Check coolant level and fan belt (see Section 4-2 and engine manual). Engine stops if engine temper-

ature is too high.

Bleed air from fuel system according to engine manual.

Have Factory Authorized Service Agent check low oil pressure switch S2 and engine coolant temper-

ature switch S3.

Periodically recharge battery (approximately every 3 months).

Replace battery.

Check voltage regulator according to engine manual.

OM-492 Page 34

Trouble Remedy

Engine does not go to low (idle) speed with Engine Control switch in Run/Idle position.

Engine does not go to high (run) speed when auxiliary power or large weld load is applied with Engine Control switch in Run/Idle position.

Engine uses oil during run-in period; wetstacking occurs.

Be sure Engine Control switch S1 is in Run/Idle position.

Remove all weld and auxiliary power loads.

Turn off remote device connected to Remote 14 receptacle RC5 (see Section 4-8).

Check for obstructed movement of throttle solenoid linkage.

Have Factory Authorized Service Agent check voltage regulator board PC8 and current transformer

CT1.

Reset circuit breaker CB9 (see Section 7-7).

Place Engine Control switch in the Run position. Have Factory Authorized Service Agent check unit.

Dry engine (see Section 9 and engine manual).

Coolant recovery tank continuously overflows.

Notes

Bleed air from radiator, and replace lost coolant (see Section 4-3).

OM-492 Page 35

SECTION 8 – ELECTRICAL DIAGRAMS

OM-492 Page 36

Figure 8-1. Circuit Diagram For Welding Generator

197 323-B

OM-492 Page 37

9-1. Wetstacking

SECTION 9 – RUN-IN PROCEDURE

1 Welding Generator Run diesel engines near rated out-

put during run-in period to properly seat piston rings and prevent wetstacking. See nameplate or rating label t o find rated output.

 Do not idle engine longer than

necessary. Piston rings seat faster if engine runs at weld/ power rpm, and the welding generator is kept loaded during run-in.

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 additional engine run-in information.

run_in4 6/99

OM-492 Page 38

9-2. 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.

1 Load Bank Turn all load bank switches Off. If

needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle.

2 Welding Generator 3 Weld Cables Connect load bank to generator

weld output terminals using proper size weld cables with correct connectors. Observe correct polarity.

Start engine and run for several minutes.

Set load bank switches and then adjust generator V/A control so load equals 225 amps at 30 volts.

Check generator and load bank meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

 Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum) place V/A 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-492 Page 39

9-3. 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.

1 Resistance Grid Use grid sized for generator rated

output. Turn Off grid. 2 Welding Generator 3 Weld Cables Connect grid to generator weld

output terminals using proper size weld cables with correct connec-

tors (polarity is not important). 4 Voltmeter 5 Clamp-On Ammeter

Connect voltmeter and ammeter as shown, if not provided on generator.

Start engine and run for several minutes.

Set grid switches and then adjust generator V/A control so load equals 225 amps at 30 volts.

Check generator and meters after first five minutes then every fifteen minutes to be sure generator is loaded properly.

 Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum), place V/A 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.

OM-492 Page 40

S-0684

SECTION 10 – AUXILIARY POWER GUIDELINES

10-1. Selecting Equipment

1 Auxiliary Power Receptacles

– Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

Be sure equipment has this symbol and/or wording.

10-2. Grounding Generator To Truck Or Trailer Frame

3 4

GND/PE

aux_pwr 2/99 – Ref. ST-159 730 / ST-800 577

1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding

Terminal 4 Grounding Cable Use #10 AWG or larger insulated

copper wire.

 If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

Electrically bond generator

frame to vehicle frame by metal-to-metal contact.

S-0854

OM-492 Page 41

10-3. Grounding When Supplying Building Systems

1 2

GND/PE

1 Equipment Grounding

Terminal 2 Grounding Cable Use #10 AWG or larger insulated

copper wire. 3 Ground Device

 Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Use ground device as stated in electrical codes.

10-4. How Much Power Does Equipment Require?

AMPERES x VOLTS = WATTS

EXAMPLE 1 : If a drill uses 4.5 amperes at 115 volts, calculate its running power

requirement in watts.

4.5 A x 115 V = 520 W

The load applied by the drill is 520 watts.

VOLTS 115 AMPS Hz

4.5 60

ST-800 576-B

1 Resistive Load A light bulb is a resistive load and

requires a constant amount of power.

2 Non-Resistive Load Equipment with a motor is a non-re-

sistive load and requires approximately six times more power while starting the motor than when running (see Section 10-8).

3 Rating Data Rating shows volts and amperes,

or watts required to run equipment.

OM-492 Page 42

EXAMPLE 2 : If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.

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

The total load applied by the three flood lamps and drill is 1120 watts.

S-0623

10-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975 3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900 5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550 1/4 HP 1850 650 1/3 HP 2400 800 1/2 HP 3500 1100

10-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000 Grain Cleaner 1/4 HP 1650 650 Portable Conveyor 1/2 HP 3400 1000 Grain Elevator 3/4 HP 4400 1400 Milk Cooler 2900 1100 Milker (Vacuum Pump) 2 HP 10500 2800 FARM DUTY MOTORS 1/3 HP 1720 720 Std. (e.g. Conveyors, 1/2 HP 2575 975 Feed Augers, Air 3/4 HP 4500 1400 Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850 3 HP 15900 3900

5 HP 23300 6800 High Torque (e.g. Barn 1-1/2 HP 8100 2000 Cleaners, Silo Unloaders, 5 HP 23300 6000 Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700 3-1/2 cu. ft. Mixer 1/2 HP 3300 1000 High Pressure 1.8 Gal/Min 500 PSI 3150 950 Washer 2 gal/min 550 PSI 4500 1400 2 gal/min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-492 Page 43

10-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400 1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900 8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600 Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800 Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500 Electric Cultivator 1/3 HP 2100 700 Elec. Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600 55 gal Drum Mixer 1/4 HP 1900 700 Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-492 Page 44

10-8. Power Required To Start Motor

4 1 3

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJKLMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

kVA/HP x HP x 1000

VOLTS

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

11.2 x 1/4 x 1000 230

= 12.2 A

VOLTS AMPS CODE 60 HP

Starting the motor requires 12.2 amperes.

AC MOTOR

230 2.5

1/4

= STARTING AMPERAGE

Hz PHASE

1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage To find starting amperage:

Step 1: Find code and use table to find kVA/HP. If code is not listed, multiply running amperage by six to find starting amperage.

Step 2: Find Motor HP and Volts. Step 3: Determine starting amper-

age (see example). Welding generator amperage out-

put must be at least twice the motor’s running amperage.

S-0624

10-9. How Much Power Can Generator Supply?

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor) loads in order from largest to smallest, and add resistive loads last.

2 5 Second Rule If motor does not start within 5

seconds, turn off power to prevent motor damage. Motor requires more power than generator can supply.

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

OM-492 Page 45

10-10. Typical Connections To Supply Standby Power

 Customer-supplied equipment is required if

generator is to supply standby power during emergencies or power outages.

120/240 Volt

60 Hz

Three-Wire

Service

Load

240 V

120 V

Neutral

240 V

120 V

1 Power Company Service

Meter

2 Main and Branch Overcurrent

Protection

3 Double-Pole, Double-Throw

Transfer Switch

Obtain and install correct switch. Switch rating must be same as or greater than the branch overcurrent protection.

4 Circuit Breakers or Fused

Disconnect Switch Obtain and install correct switch. 5 Extension Cord Select as shown in Section 10-11. 6 Generator Connections Connect terminals or plug of ade-

quate amperage capacity to cord. Follow all applicable codes and safety practices.

Turn off or unplug all equipment connected to generator before starting or stopping engine. When starting o r s t o p p i n g , t h e e ngine has low speed which causes low voltage and frequency.

7 Load Connections

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection

240 V

120 V

Ground

Item 4 is not necessary if circuit protection is already present in welding generator auxiliary power output circuit.

OM-492 Page 46

S-0405-A

10-11. 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)

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15) 37 (11) 35 4200 125 (38) 75 (23) 50 (15) 40 4800 112 (34) 62 (19) 37 (1 1) 45 5400 100 (30) 62 (19) 50 6000 87 (26) 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.

Load (Watts) 4 6 8 10 12 14

Current

(Amperes)

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38) 10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31) 15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18) 20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18) 25 6000 350 (107) 225 (69) 125 (38) 75 (23) 30 7000 300 (91) 175 (53) 100 (31) 75 (23) 35 8400 250 (76) 150 (46) 100 (31) 40 9600 225 (69) 125 (38) 75 (23) 45 10,800 200 (61) 125 (38) 50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

Load (Watts) 4 6 8 10 12 14

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

OM-492 Page 47

SECTION 11 – PARTS LIST

 Hardware i s common and

not available unless listed.

22 23

91 – Figure 11-2

105 – Figure 11-3

100

104

103

102

101

OM-492 Page 48

90 89

Figure 11-1. Main Assembly

28 – Figure 11-4

802 324-B

OM-492 Page 49

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-1. Main Assembly

1 +191 773 COVER, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1+♦193 884 COVER, generator stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 107 990 LABEL, use diesel fuel only 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 108 487 LABEL, falling equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 193 412 BRACE, hood access front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 193 411 BRACE, hood access rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 191 730 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 ♦193 881 DOOR, access stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 189 975 HINGE, door access 180deg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 193 418 TRAY, fuel spill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 +191 724 HOOD, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9+♦193 879 HOOD, access stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 194 295 LABEL, engine maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 194 320 LATCH, door access 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 191 623 LABEL, warning all panels must be in place while running 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 191 680 PLENUM, radiator cover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 ♦193 882 PLENUM, radiator cover stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 191 680 COVER, exhaust access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 ♦193 885 COVER, exhaust access stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 192 516 PIPE, exhaust elbow 1.625 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 191 675 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 176 230 LABEL, hot exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 197 271 DOOR, access removable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦197 273 DOOR, access removable stainless 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 197 259 UPRIGHT, base center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CR2 155 309 CONTACTOR, solenoid 12VDC continuous 400 A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 193 414 BRACKET, mtg gas spring front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 172 296 BALL GAS SPRING, stud .39dia 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 192 239 SPRING, pressure gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 190 323 BOOT, circuit breaker clear hex nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 197 265 BRACKET, mtg air cleaner and stop door access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 Figure 11-4 GENERATOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 193 624 ENGINE, Kubota dsl elec (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 S2 SWITCH, oil pressure (included w/engine) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 S3 192 190 SWITCH, thermo temp 230deg ±5deg F NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 192 517 GASKET, exhaust manifold 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 192 194 PIPE, exhaust flexible inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 109 591 CLAMP, muffler 1.750dia 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 191 693 GUARD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 +198 936 SHROUD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 191 341 HOSE, radiator outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 191 696 BRACKET, mtg radiator LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 197 822 RADIATOR, w/14# cap 3 row core 1.125 inlet/outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 191 687 RADIATOR ARCH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 192 195 PIPE, exhaust outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 147 923 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 192 192 MUFFLER, exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 191 695 BRACKET, mtg radiator RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 191 697 BAFFLE, lower radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 191 342 HOSE, radiator inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 191 515 BASE, fuel filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 *192 744 FILTER, fuel spin-on 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 187 462 BOTTLE, overflow w/cap and hose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 934 BRACKET, mtg coolant recovery tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 *066 113 FILTER, fuel inline .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 *196 428 FILTER, oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 192 475 SUPPORT, engine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 192 476 MOUNT, engine vibration 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-492 Page 50

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Figure 11-1. Main Assembly (Continued)

54 118 829 SCREW, shld stl sch .312-18 x .500 x .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 194 127 LINKAGE, throttle solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 145 675 NUT, .312-18 x .50 hex .37h stl pld deformed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 192 196 SOLENOID, 12VDC 46A push/hold (throttle) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 192 663 BRACKET, mtg solenoid 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 047 234 BOLT, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 047 236 FITTING, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 047 235 WASHER, seal oil copper .879 ID x 1.059 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 047 362 FITTING, pipe stl adapter spl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 008 114 HOSE, oil w/fittings 17.500 long 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 047 231 FITTING, pipe stl adapter swvl 1/2 x 1/2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 165 271 VALVE, oil drain 3/8-18 NPTF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 197 256 HOSE, elbow air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 192 188 AIR CLEANER, intake 90deg outlet 4.25 in dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*187 441 ELEMENT, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 193 026 BAND, mtg air cleaner case 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 197 227 HOSE, elbow air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 032 453 CABLE, bat neg 24.375 No. 2 awg w/clamp and .375 rng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 193 417 STRAP, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 146 237 BATTERY, stor 12V 535crk 90rsv gp 55 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 182 276 CABLE, bat pos 28.000 No. 1 awg w/clamp and .406 lug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 114 923 BOOT, insulator term post red 1/0 cable .875 OD x 1.00 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 115 000 CAP, fuel large 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 035 968 WASHER, flat 3.625 ID x 5.875 OD x .062 T rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 134 835 HOSE, SAE .312 ID x .560 OD (order by ft) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 112 090 FITTING, pipe brs elbow 1/8 NPT x 3/16 hose 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 602 902 FITTING, pipe brs valve 2-way 1/4 FPT x 1/4 NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 134 834 HOSE, SAE, .187 ID x .410 OD (order by ft) 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 145 282 FITTING, hose brs barbed elbow M 5/16 tbg x 1/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 013 466 LABEL, fuel shut-off 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 +192 191 TANK, fuel 13.1gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 512 SENDER, fuel gauge 22.500 deep tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 191 733 SUPPORT, fuel tank/inverter chassis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 172 661 BLOCK, stud connection 6posn 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 192 115 STRAP, fuel tank 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 193 300 BRACKET, fuel strap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 097 507 STRIP, rbr adh back .125 x 1.000 x 20.500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 191 317 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 192 477 MOUNT, engine vibration 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 Figure 11-2 FRONT PANEL ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 191 734 SUPPORT, inverter chassis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 190 861 LABEL, electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 141 690 GROMMET, SCR No. 8/10 panel hole .281sq .187 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 PC7 181 261 CIRCUIT CARD ASSEMBLY, filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 191 739 PLATE, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197 245 HARNESS, wiring interconnecting (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 CR1 173 069 RELAY, encl 12VDC SPDT 30A/20A 5 pin flange mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 197 147 BLOCK, term 5-4-3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 D3 135 184 DIODE BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 D4,D5 128 299 DIODE BOARD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 191 735 STRIP, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 148 850 SOCKET, relay 5 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG24 135 275 CONNECTOR, rect univ 084 15P/S 3 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

PLG15 166 680 CONNECTOR, rect univ 084 12P/S 3 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

PLG35 177 859 CONNECTOR, body 5 terminal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG33,PLG34 153 501 CONNECTOR, rect univ 039 6P/S 3 row plug (service kit) 2. . . . . . . . . . . . . . . . . . . .

S4 108 024 SWITCH, tgl DPST MC 15A 125VAC friction term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 126 KIT, foam 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Figure 11-1. Main Assembly (Continued)

197 535 HARNESS, wiring engine compartment (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC15 158 466 CONNECTOR, rect univ 084 12P/S 3 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG27 192 170 CONNECTOR, rect 250 2skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG36 192 169 CONNECTOR, rect 250 1skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG28 192 171 CONNECTOR, rect 250 3skt 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG37 192 168 CONNECTOR, rect 250 1 pin 1 row rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 092 670 CONNECTOR, rect univ 084 3P/S 1 row plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192 167 SEAL, wire univ 3P/S 1 row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 CB9,CB10 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC frict (see Figure 11-1) 2. . . . . . .

103 CB8 115 427 CIRCUIT BREAKER, man reset 1P 25A 250VAC frict (see Figure 11-1) 1. . . . . . . . . . .

104 CB7 147 658 CIRCUIT BREAKER, man rest 1P 30A 250VAC screw (see Figure 11-1) 1. . . . . . . . . . .

105 Figure 11-3 INVERTER ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

♦Optional

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

 Hardware i s common and

not available unless listed.

OM-492 Page 52

802 327

Figure 11-2. Front Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-2. Front Panel (Figure 11-1, Item 91)

1 191 455 UPRIGHT, base front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 +191 737 PANEL, front louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 138 074 LABEL, electric shock can kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 090 281 LABEL, caution do not use ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 170 391 CONN, circ ms protective cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 383 RECEPTACLE/CIRCUIT BREAKERS with leads (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RC5 143 976 CONNECTOR, circ MS/CPC 14skt sz 20 rcpt panel push-in (service kit) 1. . . . . . . . . . . . .

PLG13 115 091 CONNECTOR, rect mini 045 10skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

8 CB11,CB12 083 432 CIRCUIT BREAKER, man reset 1P 10A 250VAC frict 2. . . . . . . . . . . . . . . . . . . . . . .

9 191 736 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 190 323 BOOT, circuit breaker clear hex nut 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 601 836 NUT, 250-20 .50hex .19H brs 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC5 148 608 CIRCUIT CARD ASSEMBLY, filter HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 097 132 STAND-OFF, No. 6-32 x .375 lg .250hex brs 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 PLATE, lower (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 NAMEPLATE, upper (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 083 030 STUD, brs .250-20 x 1.750 w/hex collar 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 086 861 COVER, receptacle weatherproof 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 154 022 COVER, receptacle duplex GFCI 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 192 771 COVER, receptacle weatherproof single rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 119 014 LEVER, switch black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 021 385 BOOT, tgl switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 192 265 GAUGE, fuel elec switch w/o switchgage sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 118 058 METER, hour 12-24VDC 2.25dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 PL1 191 935 LED, red 12.0V 4 ind lights spl panel mtg round 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 CT2 192 237 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 S4 108 024 SWITCH, tgl DPST mc 15A 125VAC friction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 S1 176 606 SWITCH, ignition 4posn w/o handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 PC3 196 156 CIRCUIT CARD ASSEMBLY, front panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 RC3 132 539 RECEPTACLE, str 3P4W 50A 125/250V flush mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 CB3,CB4 141 267 CIRCUIT BREAKER, man reset 1P 50A 250VAC screw 2. . . . . . . . . . . . . . . . . . . . . .

33 RC1,RC2 192 500 RECEPTACLE, str dx grd 2P3W 20A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 CB1,CB2 093 996 CIRCUIT BREAKER, man reset 1P 20A 250VAC frict 2. . . . . . . . . . . . . . . . . . . . . . . .

35 RC6 007 469 RECEPTACLE, twlk grd 3P4W 30A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 CB13 192 565 CIRCUIT BREAKER, man reset 3P 30A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 192 566 BOOT, circuit breaker 3 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 072 253 STUD, connection single 10-32 x .500 x 1.250mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 174 991 KNOB, pointer 1.250dia x .250 ID w/spring clip 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 174 992 KNOB, pointer .820dia x .250 ID w/spring clip 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

OM-492 Page 53

 Hardware i s common and

not available unless listed.

OM-492 Page 54

802 326

Figure 11-3. Inverter Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-3. Inverter Assembly (Figure 11-1, Item 105)

1 PC2 196 148 CIRCUIT CARD ASSEMBLY, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 C3,C4,C5 174 980 CAPACITOR, elctlt 2700uf 420 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 C1 186 015 CAPACITOR, polyp film .34uf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 025 248 STAND-OFF, insul .250-20 x 1.2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 179 276 BUSHING, snap-in nyl 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 175 140 BRACKET, DI/DT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 181 197 GASKET, DI/DT rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 L3,L4 175 482 COIL, DI/DT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 109 056 CORE, ferrite E 2.164 lg x 1.09 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 185 731 WINDTUNNEL, RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 189 755 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 191 568 FOOT, mtg unit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 189 419 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 170 647 BUSHING, snap-in 1.312 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 175 084 MOTOR, fan 24VDC 3000RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 SR1 179 629 KIT, diode power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 PM1,PM2 180 110 KIT, transistor IGBT module 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 RT1,RT2 173 632 THERMISTOR, NTC 30K ohm at 25D C 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 173 631 HEAT SINK, power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 175 192 HEAT SINK, rect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 175 255 INSULATOR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 +183 551 WINDTUNNEL, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 181 853 INSULATOR, screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 189 421 BRACKET, mtg LEM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 HD1 189 567 TRANSDUCER, current 400A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 D1,D2 179 630 KIT, diode ultra-fast recovery 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 R1,C6,C7 175 194 RESISTOR/CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 185 835 LABEL, warning electric shock 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 T1 173 811 TRANSFORMER, HF 230/460 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 L1 173 563 INDUCTOR, input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 Z1 189 525 STABILIZER, output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 189 420 BRACKET, mtg capacitor/PC board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 PC1 185 749 CIRCUIT CARD ASSEMBLY, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 +189 416 WRAPPER, inverter chassis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 190 861 LABEL, electric shock and moving parts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 T2 189 481 TRANSFORMER, control 300VA 230VAC pri 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 189 422 BRACKET, mtg transformer control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 PC8 196 152 CIRCUIT CARD ASSEMBLY, voltage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 115 440 STAND-OFF, No. 6-32 x .687 lg 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 191 567 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 153 403 BUSHING, snap-in nyl .750 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 177 547 BUSHING, snap-in nyl ct-mount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 CT1 175 199 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 607 HARNESS, wiring unit (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG22 115 094 CONNECTOR, rect mini 045 4skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

RC10 168 071 CONNECTOR, rect univ 084 9P/S 3 row rcpt (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 115 091 CONNECTOR, rect mini 045 10skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG23 130 203 CONNECTOR, rect mini 045 12 skt 2 row plug (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . .

RC24 047 483 CONNECTOR, rect univ 084 15P/S 3 row rcpt (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 183 046 CABLE, LEM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

OM-492 Page 55

 Hardware i s common and

not available unless listed.

Figure 11-4. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 11-4. Generator Assembly (Figure 11-1, Item 28)

1 160 943 ENDBELL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 192 581 ROTOR, generator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 053 390 BEARING, ball rdl sgl row 1.370 x 2.830 x .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 192 600 FAN, rotor gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 +189 480 STATOR, generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 172 656 GUARD, generator wire mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 172 674 SPRING, ext .240 OD x .041 wire x 3.500pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 159 918 BAFFLE, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 193 515 ADAPTER, engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 013 367 LABEL, warning moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 170 861 STUD, stl .375-16 x 17.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 125 548 HOLDER, brush elect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 005 614 HOLDER, brush 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 *126 984 BRUSH, w/spring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 161 306 CAP, brushholder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 047 879 BAR, retaining brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

802 338

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare Parts.

OM-492 Page 56

Warranty Questions?

Call 1-877-HOBART1 for your local Hobart distributor.

Service

Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Effective January 1, 2000

(Equipment with a serial number preface of “LA” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart Welding Products., Troy, Ohio, warrants to its original ret a i l p urchaser that new Hobart 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 Hobart. THIS WARRANTY IS EXPRESSL Y IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or e i ghteen months after the equipment is sent to an International distributor.

1. 5 Years Parts – 3 Years Labor

* Original main power rectifiers * Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer .)

3. 1 Year — Parts and Labor

* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Hobart Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF

Models) * Field Options

(NOTE: Field options are covered under True

Blue for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches * Induction Heating Coils and Blankets

guarantees or warranties expressed or implied.

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2. Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than Hobart, 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.

HOBART 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 Hobart’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation bas e d u p o n actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F .O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART.

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, but may vary from province to province.

hobart standard 7/00

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Resources Available

Always provide Model Name and Serial/Style Number.

To locate a Distributor, retail or service location:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact the Delivering Carrier for:

For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

Contact your Distributor for:

Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information

and Parts) Circuit Diagrams Welding Process Handbooks

File a claim for loss or damage during shipment.

Hobart Welding Products

An Ill inoi s Tool Works Company 600 West Main Street Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1

PRINTED IN USA  2000 Hobart Welding Products. 1/00

Hobart CONTRACTOR 3025 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual