Miller Electric OM-4409 User Manual

OM-4409 206 941V

2007−05

Processes

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

TIG (GTAW) Welding

Air Carbon Arc (CAC-A)
Cutting and Gouging

With Optional Equipment:

Battery Charging

Description

Engine Driven Welding Generator And
Air Compressor

®

Big Blue Air Pak

Visit our website at

www.MillerWelds.com

File: Engine Drive

From Miller to You

Thank you and congratulations on choosing Miller. 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.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller 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 Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Compressed Air Hazards 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Additional Symbols For Installation, Operation, And Maintenance 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. California Proposition 65 Warnings 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-7. Principal Safety Standards 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-8. EMF Information 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Dangers existant en relation avec le moteur 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Dangers liés à l’air comprimé 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 9 . . . . . .

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

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

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

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

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

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

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

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

4-3. Sound Level Table 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

4-11. Air Compressor Output Curve 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

5-8. Connecting To Weld Output Terminals 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-10. Connecting To Remote 14 Receptacle RC14 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Connecting To The Air Compressor 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

TABLE OF CONTENTS

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

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

7-2. Connecting To Optional AC Power Plant 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

11-1. Troubleshooting Tables 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

15-2. Approximate Air Consumption (Cubic Feet) To Operate Pneumatic Equipment At 70-90 P.S.I.G. 68 . . .

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

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

17-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten) 76 . . . . . . . .

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

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

18-1. Positioning The Torch 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18-2. Torch Movement During Welding 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18-3. Positioning Torch Tungsten For Various Weld Joints 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.

Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex­plained in the text.

NOTICE − Indicates statements not related to personal injury.

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 1-7. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

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.

 Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

 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.

 Indicates special instructions.

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

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

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

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

 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.

 Do not touch electrode holders connected to two welding ma-

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

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 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 in inverters after stop­ping engine.

 Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

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

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

 Welding, chipping, wire brushing, and grinding

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

 Wear approved safety glasses with side shields even under your

welding helmet.

OM-4409 Page 1

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 local forced ventilation at the

arc to remove welding fumes and gases.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand 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 the 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

 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).

 Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

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

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

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

glowing embers, and flames.

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

pass them.

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

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

NOISE can damage hearing.

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.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays that

can burn eyes and skin. Sparks fly off from the weld.
 Wear an approved welding helmet fitted with a proper shade of filter

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

 Wear approved safety glasses with side shields under your

helmet.

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

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

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

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

WELDING can cause fire or explosion.

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.

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

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

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 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.

Noise from some processes or equipment can dam­age hearing.

 Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted
Medical Devices.

 Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

 Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

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

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

support or cylinder rack to prevent falling or tipping.

 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.

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

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-4409 Page 2

1-3. Engine Hazards

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.

FUEL can cause fire or explosion.

 Stop engine and let it cool off before checking or

adding fuel.

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

any sparks or open flames.

 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.
 Always keep nozzle in contact with tank when fueling.

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 doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

 To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

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

parts.

 Reinstall doors, panels, covers, or guards 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.

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 over-

flow 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.

Using a generator indoors CAN KILL
YOU IN MINUTES.

 Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

 NEVER use inside a home or garage, EVEN IF

doors and windows are open.

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

vents.

BATTERY ACID can BURN SKIN and EYES.

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

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.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on equip-

ment.

 To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

1-4. Compressed Air Hazards

BREATHING COMPRESSED AIR can
cause serious injury or death.

 Do not use compressed air for breathing.
 Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

 Wear approved safety goggles.
 Do not direct air stream toward self or others.

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.

TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.

 Release air pressure from tools and system be-

fore servicing, adding or changing attach­ments, or opening compressor oil drain or oil fill
cap.

OM-4409 Page 3

HOT METAL from air arc cutting and

READ INSTRUCTIONS.

gouging can cause fire or explosion.

 Do not cut or gouge near flammables.
 Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

 Do not touch hot compressor or air system

parts.

 Let system cool down before touching or ser-

vicing.

 Read Owner’s Manual before using or servic-

ing unit.

 Stop engine and release air pressure before

servicing.

 Use only genuine replacement parts from the

manufacturer.

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

FIRE OR EXPLOSION hazard.

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

combustible surfaces.

 Do not install unit near flammables.

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

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

FALLING UNIT can cause injury.

 Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).

 Lift and support unit only with proper equipment

and correct procedures.

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

extend beyond opposite side of unit.

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.

FLYING SPARKS can cause injury.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

OVERUSE can cause OVERHEATING.

 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.

 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.

MOVING PARTS can cause injury.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

OM-4409 Page 4

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine replacement parts from the

manufacturer.

 Perform engine and air compressor mainte-

nance and service according to this manual
and the engine/air compressor (if applicable)
manuals.

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

promptly 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.

1-6. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

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.

 Electromagnetic energy can interfere with

sensitive electronic equipment such as micro­processors, 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 to 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.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc­tive harm.

For Diesel Engines:

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

1-7. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: [phone], website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic 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 power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

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

Ontario, Canada L4W 5NS (phone: [phone] or in Toronto
416-747-4044, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (phone: [phone], web­site: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 Regional Offices—phone for
Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

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

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

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

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

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

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-4409 Page 5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

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

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan­gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

2-2. 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 et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-7. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
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
internes de l’appareil sont également sous tension à ce moment-là.
En soudage semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en
contact avec le fil de soudage sont sous tension. Des matériels mal
installés ou mal mis à la terre présentent un danger.

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

tant pas de trous.

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

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

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

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

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

MENT si le procédé de soudage le demande.

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

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

 Des précautions de sécurité supplémentaires sont requises dans

des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures mé­talliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder

OM-4409 Page 6

 Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas tra­vailler seul!

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

l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR

1910.147 (voir normes de sécurité).

 Installer et mettre à la terre correctement cet appareil conformé-

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

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

s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.

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

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

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

protégez−les contre les étincelles et les pièces métalliques chau­des.

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

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

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

sante ou mal épissés.

 Ne pas enrouler les câbles autour du corps.
 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.

 Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

 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 câble de retour de façon à obtenir un bon contact métal-

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

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

contact avec tout objet métallique.

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.

DES PIÈCES CHAUDES peuvent

-

e

­r

e

s

u

e

n

o
e

e

e

u
n

e

f

e

c

e

provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

DES PIECES DE METAL ou DES SA­LETES peuvent provoquer des bles­sures dans 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 risquent de projeter du laitier.

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

facial.

LES FUMÉES ET LES GAZ peuvent êtr
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’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

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

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

approuvé.

 Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.

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

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

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

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

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

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

LES ACCUMULATIONS DE GAZ ri
quent de provoquer des blessures o
même la mort.

 Fermer l’alimentation du gaz protecteur en cas d

non utilisation.

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

respirateur d’adduction d’air homologué.

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

Le rayonnement de l’arc du procédé de soudag

génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

 Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage
(voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter des vêtements confectionnés avec des matières résistan-

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

LE SOUDAGE peut provoquer un in
cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites pe

provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchau
fement ou un incendie. Avant de commencer le soudage, vérifier
s’assurer que l’endroit ne présente pas de danger.

 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.

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

sur des substances inflammables.

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

de métal chaud.

 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 déclencher un incendie de l’autre côté.

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

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

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

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

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

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

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

lées.

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

électrode ou couper le fil à la pointe de contact.

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

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

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

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

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

ce d’étincelles incandescentes ni de flammes.

 Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

LE BRUIT peut affecter l’ouïe.

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

 Porter des protections approuvés pour les or

les si le niveau sonore est trop élevé.

OM-4409 Page 7

LES CHAMPS MAGNETIQUES peuv-

a

a

a
n

e

s
s

o

e

s

e

t

o

,

-

e

­r

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

ent affecter des implants médicaux.

 Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

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

avant de s’approcher des opérations de soudage à l’arc, de sou­dage par points, de gougeage, du coupage plasma ou de chauf­fage par induction.

 Tenir les bouteilles éloignées des circuits de soudage ou autres

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

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

Si des BOUTEILLES sont endomm
gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du g

sous haute pression. Si une bouteille est endomm
gée, elle peut exploser. Du fait que les bouteilles de gaz fo
normalement partie du procédé de soudage, les manipuler av
précaution.

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

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

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

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

 Utiliser les équipements corrects, les bonnes procédures et suffi-

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

2-3. Dangers existant en relation avec le moteur

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

circuits électriques.

une bouteille.

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

bouteille.

d’utilisation ou de branchement de la bouteille.

samment de personnes pour soulever et déplacer les bouteilles.

l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.

L’EXPLOSION DE LA BATTERIE peu
RENDRE AVEUGLE.

 Toujours porter une protection faciale, des gant

en caoutchouc et vêtements de protection lor
d’une intervention 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 véhicules de démarrage rapide.

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

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

dernier lieu.

LE CARBURANT MOTEUR peut prov
quer un incendie ou une explosion.

 Arrêter le moteur avant de vérifier le niveau d

carburant ou de faire le plein.

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

ou d’une flamme nue.

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

pour son expansion.

 Faire attention de ne pas renverser de carburant. Nettoyer tou

carburant renversé avant de faire démarrer le moteur.

 Jeter les chiffons dans un récipient ignifuge.
 Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

DES ORGANES MOBILES peuvent pr
voquer des blessures.

 Ne pas approcher les mains des ventilateurs

courroies et autres pièces en mouvement.

 Maintenir fermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

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

OM-4409 Page 8

 Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour
effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

 Pour empêcher tout démarrage accidentel pendant les travaux

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

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

des organes mobiles.

 Remettre en place les panneaux ou les dispositifs de protection et

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

 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 interven-

tion sur le générateur.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher à mains nues les parties chau

des.

 Prévoir une période de refroidissement avant d

travailler à l’équipement.

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

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

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

 Il est préférable de vérifier le liquide de refroi-

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

 Toujours vérifier le niveau de liquide de refroidissement dans le

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

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

me suivant.

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

le bouchon du radiateur.

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

avant d’enlever le bouchon.

L’utilisation d’un groupe autonome

t
,

e

-

e

s

r

u

à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.

 Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi­ble et inodore.

 JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

 Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

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.

L’ACIDE DE LA BATTERIE peut pro­voquer des brûlures 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.

2-4. Dangers liés à l’air comprimé

RESPIRER L’AIR COMPRIMÉ peut pro­voquer des blessures graves ou causer
la mort.

 Ne pas utiliser l’air comprimé pour respirer.
 Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

L’AIR COMPRIMÉ peut provoquer
des blessures.

 Porter des lunettes de sécurité approuvées.
 Ne pas diriger le jet d’air vers d’autres ou

soi-même.

L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo­quer des blessures.

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

système avant d’effectuer la maintenance,
avant de changer ou de rajouter des éléments
ou avant d’ouvrir la purge ou le bouchon de
remplissage d’huile.

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.

Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in­cendie ou une explosion.

 Ne pas couper ou gouger à proximité de pro-

duits inflammables.

 Surveillez et garder un extincteur à proximité.

DES PIECES CHAUDES peuvent provo­quer des brûlures et blessures.

 Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

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

maintenance.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

 N’utiliser que les pièces de rechange recommandées par le

constructeur.

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

Risque D’INCENDIE OU D’EXPLO­SION.

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

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de pro-

duits inflammables.

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

mentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.

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

que les fourches sont suffisamment longues pour dépasser d
côté opposé de l’appareil.

LA CHUTE DE L’APPAREIL peut blesser.

 Utiliser l’anneau de levage pour lever l’appareil e

les accessoires correctement installées seuls
PAS les bouteilles de gaz. Ne pas dépasser l
poids nominal maximal de l’œilleton (voir les spé
cifications).

 Ne lever et ne soutenir l’appareil qu’avec d

l’équipement approprié et en suivant le
procédures adéquates.

OM-4409 Page 9

LE SURCHAUFFEMENT peut endom-

e

-

-

,

t

a

-

n

u

-

mager le moteur électrique.

 Arrêter ou déconnecter l’équipement avant d

démarrer ou d’arrêter le moteur.

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

dommager le moteur électrique à cause d’une tension et d’une fré
quence trop faibles.

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

s’il y a lieu.

LES ÉTINCELLES VOLANTES ris­quent de provoquer des blessures.

 Porter un écran facial pour protéger le visage e

les yeux.

 Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cette manœuv
re est à exécuter dans un endroit sûr lorsque l’o
porte l’équipement homologué de protection d
visage, des mains et du corps.

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

stance inflammable.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

sonnes ou toute pièce mécanique en enga­geant le fil de soudage.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

 Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

 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 remor-

que comme indiqué dans le manuel s’y rappor­tant.

LIRE LES INSTRUCTIONS.

 Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

 N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

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

seur d’air suivant les instructions dans ce manuel ou le manuel
du moteur/compresseur (si applicable).

LE RAYONNEMENT HAUTE FRÉ­QUENCE (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 électri-

cien qualifié les interférences résultant de l’installation.

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

pareil.

 Effectuer régulièrement le contrôle et l’entretien de l’installation.
 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 un blindage pour réduire les
interférences éventuelles.

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

 L’énergie électromagnétique risque de provo-

quer 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

soudage 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 équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

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

tes, il incombe à l’utilisateur de prendre des mesures supplé­mentaires telles que le déplacement du poste, l’utilisation de câ­bles blindés, l’utilisation de filtres de ligne ou la pose de protec­teurs dans la zone de travail.

OM-4409 Page 10

2-6. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi­ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipu­lation.

2-7. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone :
1-877-413-5184, site Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protec­tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan­tilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada

Pour les moteurs à essence :

Les gaz d’échappement des moteurs contiennent des pro­duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.

Pour les moteurs diesel :

Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com­me provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,

P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus­try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin­tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).

2-8. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

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 électromagnéti­ques pendant le soudage ou le coupage.

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

1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.

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

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

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

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

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc­tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.

OM-4409 Page 11

SECTION 3 − DEFINITIONS

3-1. Symbols And Definitions

Stop Engine

Check engine belt Check Air Cleaner Starting Aid Engine

Battery (Engine)

OPT

Do Not Switch

Under Load

Check Injectors/

Pump

Hourmeter (HM) Air Pressure Temperature Air Compressor

Positive Negative Wire Feed Welding Arc

Fast (Run, Weld/

Power)

Jump start/Battery

Charge

Read Operator’s

Manual

Check Valve

Clearance

Slow (Idle) Start Engine

Battery Charge Jump Start

Certified/Trained

Mechanic

Fuel

Engine Oil

Engine Coolant

Temperature

3

A

Amperes

Volts Panel/Local Remote

V

Output

Stick (SMAW)

Welding

Three Phase

DC Electrode

Positive

Circuit Protector Time

On Off

1

Direct Current

(DC)

Constant Current

(CC)

Single Phase

DC Electrode

Negative

h

Alternating

Current (AC)

MIG (GMAW)

Welding

Air Carbon Arc

Cutting (CAC-A)

Work Connection

Hours

s

Gas Tungsten Arc

Welding (TIG)

Constant Voltage

(CV)

Protective Earth

(Ground)

Electrode

Connection

Seconds

OM-4409 Page 12

SECTION 4 − SPECIFICATIONS

DC,

,

600 A

120/240 V AC

Single Phase/Three Phase,

4-1. Weld, Power, And Engine Specifications

Welding

Mode

CC/DC 20 − 750 A

CV/DC 14 − 40 V

CC/AC

(Optional)

Battery

Charge/

Jump

Start

Weld

Output

Range

20 - 575

12/24 V

Rated

Welding

Output

500 A,

40 Volts

DC,

100% Duty

Cycle

600 A,

44 Volts

DC,

40% Duty

Cycle

750 A,
12 Volt

Jump Start

750 A,
24 Volt

Jump Start

Maximum

Open-Circuit

Voltage

(Nominal)

95

56

,

64

14/28

4-2. Air Compressor Specifications

Compressor Model

And Type

Air Output At Effective

Working Pressure

Generator Power

Rating

Standard

Single-Phase,

4 kVA/kW, 34/17 A,

120/240 V AC

50/60 Hz

3-Phase Generator

Option*

Single-Phase/Three-Phase,

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

120/240 VAC, 60 Hz

*In Addition To Standard

4 kVA/kW Generator Power

,

Factory Pressure

Setting

Engine

DEUTZ

Deutz BF4M2011

Oil-Cooled,

Four-Cylinder,

Turbo-Charged

63.4 HP Diesel Engine

Safety Relief
Valve Rating

Engine

Oil

Capacity

11 qt

(10.4 L)

Air Compressor

Oil Capacity

Fuel Tank

Capacity

25 gal
(95 L)

Ingersoll Rand CE55 G

Rotary Screw

60 scfm (1.7 m3 min−1),

100 psi (690 kPa),

100% Duty Cycle

4-3. Sound Level Table

Idle Speed (1235 rpm)

96.6 Lwa sound power

Air Compressor On

Air Compressor Off

71.7 dBa at 23 ft (7 m)

77.2 dBA 3.3 ft (1 m)
from front panel

94.6 Lwa sound power

69.7 dBa at 23 ft (7 m)

74.5 dBA 3.3 ft (1 m)
from front panel

125 psi (862 kPa) 150 psi (1034 kPa) 4 qt (3.8 L)

Weld/Power Speed

(1850 rpm)

102.8 Lwa sound power

77.9 dBa at 23 ft (7 m)

83.0 dBA 3.3 ft (1 m)
from front panel

100.6 Lwa sound power

75.7dBa at 23 ft (7 m)

78.8 dBA 3.3 ft (1 m)
from front panel

40 Volts DC At 500

Amps

103.9 Lwa sound power

79.0 dBa at 23 ft ( 7 m)

89.8 dBA 3.3 ft (1 m)
from front panel

103.0 Lwa sound power

78.1dBa at 23 ft (7 m)

86.0 dBA 3.3 ft (1 m)
from front panel

44 Volts DC At 600

Amps

106.0 Lwa sound power

81.1 dBa at 23 ft (7 m)

93.3 dBA 3.3 ft (1 m)
from front panel

104.5 Lwa sound power

79.6 dBa at 23 ft (7 m)

91.8 dBA 3.3 ft (1 m)
from front panel

OM-4409 Page 13

4-4. Dimensions, Weights, And Operating Angles

G

ti

D

Dimensions

Height

Width

Depth 69-1/2 in (1765 mm)

A 69-1/2 in (1765 mm)
B* 55-7/8 in (1419 mm)
C* 46-3/8 in (1178)
D* 11 in (279 mm)

E 27-1/2 in (699 mm)

F 1 in (25 mm)

G 29-13/16 in (757 mm)

H

* With mounting brackets in center

position. Dimensions vary with loca­tion of mounting brackets.

No fuel: 2010 lb (907 kg)

Lifting Eye Weight Rating

2185 lb (993 kg) Maximum

54-1/2 in (1384 mm)

(to top of muffler)

28-1/2 in (724 mm)

(mtg. brackets turned in)

30-3/4 in (781 mm)

(mtg. brackets turned out)

9/16 in (14 mm) Dia.

4 Holes

Weight

w/fuel: 2185 lb (993 kg)

A

B

C

H

D

Front Panel End

E

! Do not exceed tilt angles or engine could

be damaged or unit could tip.

! Do not move or operate unit where it could

p.

30°

30°

20°
20°

F

802 161-A

803 231

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4409 Page 14

4-5. Stick And MIG Volt-Ampere Curves

A. DC Stick Mode

100

80

60

40

DC VOLTS

20

0

0 100 200 300 400 500 600 700 800 900 1000

B. AC Stick Mode (Optional)

100

80

DC AMPERES

Ranges
300 − Max
185 − 525
125 − 400
85 − 250
55 − 125

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

60

40

AC VOLTS

20

0

0 100 200 300 400 500 600 700

C. MIG Mode

100

80

60

40

DC VOLTS

AC AMPERES

MAX

20

MIN

0

0 100 200 300 400 500 600 700 800 900 1000

DC AMPERES

208 135 / 203 415 / 208 956

OM-4409 Page 15

4-6. TIG Volt-Ampere Curves

A. DC TIG Mode

100

80

60

40

DC VOLTS

20

0

0 50 100 150 200 250 300 350 400 450 500 550 600 650 700

The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.

Ranges
60−450

40−330
30−220
20−110

DC AMPERES

B. AC TIG Mode (Optional)

100

80

60

40

AC VOLTS

20

0

0 100 200 300 400 500 600 700

AC AMPERES

OM-4409 Page 16

208 136 / 208 957

4-7. Fuel Consumption

3.00

2.75

2.50

2.25

2.00

1.75

1.50

1.25

US Gal./Hr.

1.00

0.75

0.50

0.25

0.00

IDLE

050

100 150 200 250 300 350 400 450 500 550 600

DC WELD AMPERES AT 100% DUTY CYCLE

The curve shows typical fuel use
under weld or generator power
loads.

w/ Air Output

208 211

4-8. Duty Cycle And Overheating

100% Duty Cycle At 500 Amperes

Continuous Welding

40% Duty Cycle At 600 Amperes

4 Minutes Welding 6 Minutes Resting

1000

800

600
500

400

300
250

200

WELD AMPERES

150

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

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

100

10

15 20 25 30 40 50 60 80 100

% DUTY CYCLE

202 356

OM-4409 Page 17

4-9. Generator AC Power Curve

300

150

250

125

200

100

150

75

AC VOLTS

100

50

50

25

0

0

0 5 10 15 20 25 30

AC AMPERES IN 240V MODE

0102030405060

AC AMPERES IN 120V MODE

The ac power curve shows the gen­erator power in amperes available
at the 120 and 240 volt receptacles.

Notes

193 018

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-4409 Page 18

4-10. Optional 3-Phase Generator Power Curves

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

280

140

270

135

260

130

250

125

240

120

230

115

220

110

AC VOLTS

105

210

100

200

95

190
180

90

0

20 40 60 80 100

AC AMPERES

The ac power curves show the gen­erator power available in amperes
at the single-phase 120/240 volt re­ceptacle or three-phase 240 volt
terminals.

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

280

260

240

220

AC VOLTS

200

180

0 10203040506070

AC AMPERES

197 472 / 197 473

OM-4409 Page 19

4-11. Air Compressor Output Curve

140

120

100

80

Idle

60

40

20

POUNDS PER SQUARE INCH (PSI)

0

0 102030405060708090100

The air output curve shows the vol­ume and pressure of air available
from the air compressor.

CUBIC FEET PER MINUTE (CFM)

4-12. Optional Battery Charging Output Curve

50
45
40
35
30
25
20

DC VOLTS

15
10

5
0

0

100 200 300 400 500 600 700 800 900 1000

208 955

The battery charging curves show
the charging amperage and voltage
output of the welding generator.

As battery voltage nears the charg­ing voltage, charging current de­creases.

OM-4409 Page 20

DC AMPERES

210 269

4-13. Manufacturing Rating Label

OM-4409 Page 21

SECTION 5 − INSTALLATION

5

-1. Installing Welding Generator

! Always securely fasten weld-

ing generator onto transport

Movement

OR OR

Location/Airflow Clearance

OR

OR

vehicle or trailer and comply
with all DOT and other applica­ble codes.

! Always ground generator

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

! If unit does not have GFCI re-

ceptacles, use GFCI-protected
extension cord.

NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.

 See Section 4-4 for lifting eye rat-

ing.

 See Section 5-2 for mounting in-

formation.

Grounding:

1 Equipment Grounding Terminal

(On Front Panel)
2 Grounding Cable (Not Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger insu­lated copper wire.

18 in

(460 mm)

18 in

(460 mm)

Grounding

GND/PE

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

1

2

Electrically bond generator frame to
vehicle frame by metal-to-metal contact.

3

! Bed liners, shipping skids, and some running

gears insulate the welding generator from the
vehicle frame. Always connect a ground wire
from the generator equipment grounding termi­nal to bare metal on the vehicle frame as shown.

OM-4409 Page 22

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

5-2. Mounting Welding Generator

Supporting The Unit

Inadequate support.

! Do not use flexible mounts.

Using Mounting Brackets

! Do not weld on base. Weld-

ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.

! Do not mount unit by sup-

porting the base only at the
four mounting brackets.

2

OR

1

1

2

Use cross-supports to ade­quately support unit and pre­vent damage to base.

Mounting Surface:

1 Cross-Supports
2 Mounting Brackets (Supplied)
Mount unit on flat surface or use

cross-supports to support base.
Secure unit with mounting brack­ets.

3 1/2 in Bolt And Washer

(Minimum − Not Supplied)

4 3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.

Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).

To Weld Unit In Place:

Weld unit to truck or trailer only at
the four mounting brackets.

Tools Needed:

9/16 in

Welding Unit In Place

Bolting Unit In Place

2

4

3

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

OM-4409 Page 23

5-3. Installing Optional Spark Arrestor Muffler

10

9

1

7

! Stop engine and let cool.

1 Spark Arrestor Muffler
2 Double-Flanged Elbow
3 Nut
4 Flat Washer
5 Mount
6 Bracket
7 Screw

2

8 Single-Flanged Elbow
9 Rain Cap
10 Clamp
Loosely assemble components as

shown.

 Mount the muffler with the clean-

out plug to the outside.

After assembly, final-tighten all
clamps and hardware.

 Be sure to tighten rain cap

mounting screw.

8

3

6

5

4

Tools Needed:

OM-4409 Page 24

7/16, 1/2 in

803 230

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

3

2

1

4

! Always wear a face shield,

rubber gloves and protective
clothing when working on a
battery.

Remove battery from unit.
1 Vent Caps
2 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)
3 Well
Fill each cell with electrolyte to

bottom of well (maximum).

! Do not overfill battery cells.

Wait ten minutes and check electro­lyte level. If necessary, add electro­lyte to raise to proper level. Reins­tall vent caps.

4 Battery Charger

! Read and follow all instruc-

tions supplied with battery

charger.

Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am­peres. Disconnect charging cables
and install battery.

 When electrolyte is low, add

only distilled water to cells to

maintain proper level.

5 A For 30 Minutes

Tools Needed:

30 A For 12 Minutes

5-5. Connecting The Battery

! Connect Negative (−) Cable Last.

+

OR

+

−

drybatt1 6/05 − S-0886

 Reinstall cover after connecting battery.

−

Tools Needed:

1/2 in

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

OM-4409 Page 25

5-6. Using The Optional Battery Disconnect Switch

1

OFF

ON

! Stop engine.

1 Battery Disconnect Switch
The battery disconnect switch dis-

connects battery voltage from the
circuit. When the switch is turned
Off, the front panel controls do not
work.

To run unit, turn switch to On posi­tion. To prevent unit from running,
turn switch to Off position.

The switch may be locked using a
customer-supplied padlock.

Notes

803 228 / Ref. 803 324

Start Your Professional

Welding Career Now!

OM-4409 Page 26

400 Trade Square East, Troy, Ohio 45373

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

Over 80,000 trained

since 1930!

5-7. Engine/Compressor Prestart Checks

Diesel

Full

Engine Oil

Compressor

Oil

1

To o

High

 Check all engine/compressor fluids

daily.

Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil. The
automatic shutdown system stops engine if
oil pressure is too low or coolant 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 14.

Fuel

NOTICE − Do not use gasoline. Gasoline
will damage engine.

Add fresh diesel fuel before starting to pre­vent air from entering the fuel system (see
engine maintenance label for fuel specifica­tions). Leave filler neck empty to allow room
for expansion.

Engine stops if fuel level is low on units with
low fuel shutdown option. Do not run out of
fuel or air may enter fuel system and cause
starting problems. See engine manual to
bleed air from fuel system.

Engine 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 for engine oil
specifications).

Compressor Oil

1 Compressor Oil Level Indicator (On

Tank)

Check oil with unit on level surface. Add oil

Full

To o

Low

Full

if oil is not up to full mark on indicator (see
maintenance label for oil specifications).

Cold Weather Starting

 To improve cold weather starting:

Use Starting Aid switch (see Section
6-1).

Keep battery in good condition. Store
battery in warm area.

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

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

803 228

OM-4409 Page 27

5-8. Connecting To Weld Output Terminals

! Stop engine.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

! Failure to properly connect weld

cables may cause excessive heat and
start a fire, or damage your machine.

3 Weld Output Terminal
4 Supplied Weld Output Terminal Nut
5 Weld Cable Terminal
6 Copper Bar
Remove supplied nut from weld output termi-

nal. Slide weld cable terminal onto weld output
terminal and secure with nut so that weld cable
terminal is tight against copper bar. Do not

place anything between weld cable termi­nal and copper bar. Make sure that the sur­faces of the weld cable terminal and cop­per bar are clean.

Stick And TIG Welding

For Stick welding Direct Current Electrode
Positive (DCEP), connect electrode hold­er cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right.

For Stick and TIG Direct Current Elec­trode Negative (DCEN), connect elec­trode holder cable to Negative (−) terminal
on right and work cable to Positive (+) ter­minal on left.

If equipped with optional Polarity/AC Se­lector switch, connect electrode holder
cable to Electrode terminal on left and
work cable to Work terminal on right.

MIG And FCAW Welding

For MIG welding Direct Current Electrode
Positive (DCEP), connect wire feeder
cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on
right. Use Process/Contactor switch to
select type of weld output (see Section
6-3).

For MIG and FCAW Direct Current Elec­trode Negative (DCEN), connect wire
feeder cable to Negative (−) terminal on
right and work cable to Positive (+) termi­nal on left. Use Process/Contactor switch
to select type of weld output (see Section
6-3).

If equipped with optional Polarity/AC Se­lector switch, connect wire feeder cable to
Electrode terminal on left and work cable
to Work terminal on right.

Tools Needed:

3/4 in

3

4

5

1

2

6

Do not place

anything between

weld cable terminal

and copper bar.

OM-4409 Page 28

Correct Installation

Incorrect Installation

803 231 / 803 778-A

5-9. Selecting Weld Cable Sizes*

Terminals

Weld Output

Terminals

! Turn off power before

connecting to weld
output terminals.

! Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

100 ft (30 m) or Less

10 − 60%

Duty

Cycle

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

Not Exceeding***

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

60 − 100%

Duty

10 − 100% Duty Cycle

Cycle

400 ft

(120 m)

250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120)

500 2/0 (70) 3/0 (95) 4/0 (120)

600 3/0 (95) 4/0 (120)

700 4/0 (120)

800 4/0 (120)

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

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use S-0007-F

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

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

2 ea. 2/0

(2x70)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

2 ea. 2/0

(2x70)

2 ea. 3/0

(2x95)

2 ea. 4/0

(2x120)

2 ea. 4/0

(2x120)

3 ea. 3/0

(3x95)

3 ea. 4/0

(3x120)

4 ea. 4/0

(4x120)

4 ea. 4/0

(4x120)

Notes

OM-4409 Page 29

5-10. Connecting To Remote 14 Receptacle RC14

24 VOLTS AC

OUTPU

OUTPUT

Socket* Socket Information

A 24 volts ac. Protected by sup-

plementary protector CB5.

24 VOLTS AC

B Contact closure to A completes

24 volt ac contactor control
circuit.

C Output to remote control:+10

volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.

*The remaining sockets are not used.

Notes

OR

803 231

REMOTE

D Remote control circuit common.

T

CONTROL

115 VOLTS AC

GND

NEUTRAL G Circuit common for 24 and 115

E DC input command signal: 0 to

+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.

115 volts, 10 amperes, 60 Hz
ac. Protected by supplementary

I

protector CB6.

Contact closure to I completes
115 volt ac contactor control

J

circuit.

K Chassis common.

volt ac circuit.

OM-4409 Page 30

5-11. Connecting To The Air Compressor

2

! Stop engine and release air pres-

sure before servicing compressor.

Open Position

Closed Position

1

803 231

! Air pressure is present at air shutoff

valve whenever Air Pressure Gauge
on front panel indicates air
pressure.

1 3/4 in NPT Air Pressure

Fitting
2 Air Shutoff Valve
Connect air hose with 3/4 in NPT fitting (not

supplied) to air shutoff valve.

Be sure valve is in open position when us­ing air compressor.

The compressor runs and air pressure is
available whenever the engine is running
and the front panel Compressor switch is
moved to the On position (see Section 6-1).

Run engine at weld/power speed for maxi­mum air compressor output. Compressor
output is reduced when engine is running at
idle speed.

The air compressor will not start if still under
pressure. If air compressor is turned off,
wait for air pressure to bleed off (about 20
seconds) before turning air compressor on
again.

 Using the air compressor does not sig-

nificantly affect weld or generator pow­er output.

OM-4409 Page 31

SECTION 6 − OPERATING THE WELDING GENERATOR

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

11 15 1612 657

3

4

8

17

OM-4409 Page 32

10

14

18

13

1

2

9

803 229 / 217 356-A

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

Engine Starting Controls

1 Starting Aid Switch
Use switch to energize starting aid for cold

weather starting.
Push switch up for 60 seconds to operate the

starting aid (intake air heater) before cranking
engine (see starting instructions following).

2 Engine Control Switch
Use switch to start engine, select engine

speed, and stop engine.
In Run position, engine runs at weld/power

speed. In Run/Idle position, engine runs at
idle speed with no generator power or weld
load, and weld/power speed with load ap­plied.

The air compressor load does not affect en­gine speed. Run engine at weld/power speed
for maximum air compressor output.

To Start:

 If engine does not start, let engine come

to a complete stop before attempting re­start.

Above 32 F (0 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.

Below 32 F (0 C) using starting aid
switch:

Turn Engine Control switch to Run/Idle posi­tion. Push Starting Aid switch up for 60 sec­onds. While still holding Starting Aid switch,
turn Engine Control switch to Start. Release
Engine Control switch and Starting Aid switch
when engine starts.

To Stop: turn Engine Control switch to Off
position.

Engine/Compressor Gauges

3 Engine Hour Meter
Use gauge to monitor engine running time for

scheduling maintenance.
4 Fuel Gauge
Use gauge to check fuel level. Engine stops

if fuel level is low on units with low fuel shut­down option.

To check fuel level when engine is not run­ning, turn Engine Control switch to Run/Idle
position.

5 Air Pressure Gauge
Use gauge to check compressor air pressure.

6 Engine Oil Pressure Gauge
Normal pressure is 30 − 60 psi (206 − 414

kPa). Engine stops if pressure is below 20 psi
(138 kPa).

7 Engine Temperature Gauge
Normal temperature is 212 - 239° F (100 -

115 ° C). Engine stops if temperature exceeds
270° F (132° C).

8 Battery Voltmeter
Use gauge to check battery voltage and moni-

tor the engine charging system. The meter
should read about 14 volts dc when the en­gine is running, and about 12 volts dc when
the engine is stopped.

9 Air Compressor Hour Meter (Optional)
Use gauge to monitor compressor running

time for scheduling maintenance.

Weld Controls

10 Process/Contactor Switch
See Section 6-3 for Process/Contactor

switch information.
11 Ampere Range Switch

NOTICE − Do not switch under load.

Use switch to select weld amperage range.
Use all five ranges for Stick welding, and the

lowest four ranges for TIG welding. Read the
upper set of numbers at each range for Stick
welding and the lower set at each range for
TIG welding.

Use the highest range for MIG welding and for
cutting and gouging (CAC-A).

For most welding applications, use lowest
amperage range possible to help prevent arc
outages.

12 Voltage/Amperage Adjust Control
With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Panel/Remote Switch in Remote posi­tion, control limits the remote amperage in
TIG mode, but has no effect in Stick and MIG
modes.

Weld output would be about 263 A DC with
controls set as shown (50% of 125 to 400 A).

 The numbers around the Voltage/Amper-

age Adjust control are for reference only

and do not represent an actual percent­age value.

13 Panel/Remote Switch And Remote 14

Receptacle

Use switch to select front panel or remote
voltage/amperage control. For remote con­trol, place switch in Remote position and con­nect remote control to Remote 14 receptacle
RC14 (see Sections 5-10 and 6-4).

14 Polarity/AC Selector Switch (Optional)

Or Output Selector Switch (Optional)

NOTICE − Do not switch under load.

Use Polarity/AC selector switch to select AC
or DC weld output and DC weld output po­larity.

Use Output Selector switch to select AC
Weld, DC Weld, or battery charge output (see
Section 8-1).

Weld Meters

15 AC/DC Voltmeter (Optional)
Voltmeter displays voltage at the weld output

terminals, but not necessarily the welding arc
due to resistance of cable and connections.

16 AC/DC Ammeter (Optional)
Ammeter displays amperage output of the

unit.

Air Compressor Controls

17 Air Compressor Switch
Use switch to turn air compressor on and off.

Air pressure is present at the compressor air
shutoff valve whenever the compressor is
running. The compressor shuts off when the
engine stops. To use air, the compressor must
be turned on each time the engine is started.

The air compressor will not start if still under
pressure. If air compressor is turned off, wait
for air pressure to bleed off (about 20 sec­onds) before turning air compressor on again.

 To extend clutch bearing life, cycle air

compressor off and on once every two
hours during periods of extended use.

18 Air Shutoff Valve

! Air pressure is present at valve when-

ever Air Pressure Gauge (item 5) indi­cates air pressure.

Close valve to stop air flow when connecting
or changing tools or air hoses (see Section
5-11).

OM-4409 Page 33

6-3. Process/Contactor Switch

1 Process/Contactor Switch

! Weld output terminals are ener-

gized when Process/Contactor
switch is in a Weld Terminals Al­ways On position and the en­gine is running.

! DC voltage is still present at the

1

weld terminals when Process/
Contactor switch is in the Re­mote On/Off Switch Required −
Stick position and the engine is
running.

Use switch to select weld process and
weld output on/off control (see table be­low and Section 6-4).

Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.

Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.

Use Stick position for air carbon arc
(CAC-A) cutting and gouging.

When switch is in a Stick position, the
arc drive (dig) circuit provides addition­al amperage during low voltage (short
arc length conditions) to prevent “stick­ing” electrodes.

The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.

 The engine auto idle option does

not work in the Remote On/Off
Switch Required-TIG mode.

Process/Contactor Switch Settings

Switch Setting Process Output On/Off Control Engine Auto Idle (Optional)

Remote On/Off Switch Re­quired − TIG, HF Required

Or Scratch Start TIG

Remote On/Off Switch

Required − Stick

Remote On/Off Switch
Required − CV Feeder

Using Remote

Weld Terminals Always On −

Wire

Weld Terminals Always On −

Stick

Weld Terminals Always On −

TIG, Scratch Start

GTAW With HF Unit, Pulsing

Device, Or Remote Control

Stick (SMAW) With Remote On/Off At Remote 14 Receptacle Active

MIG (GMAW) At Remote 14 Receptacle Active

MIG (GMAW) Electrode Hot Active

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

TIG Scratch Start (GTAW) Electrode Hot Active

At Remote 14 Receptacle Not Active

Electrode Hot Active

217 356-A

OM-4409 Page 34

6-4. Using Remote Voltage/Amperage Control

1

1 Remote 14 Receptacle RC14
Connect optional remote control to

RC14 (see Section 5-10).

803 231

Example: Combination Remote Amperage Control (Stick)

Set

Panel/Remote

Switch

Example: Combination Remote Amperage Control (TIG)

Set Remote

Process

Set Range Control Not Used

In Remote On/Off

Switch Required −

Stick Mode

Process = Stick (Using Remote On/Off)

In Example:

Range = 125 to 400 A DC

Min = 125 A DC

Max = 400 A DC

Max (400 A DC)

Min (125 A DC)

Adjust Optional Remote Control

In Example:

Process = TIG (Using Remote On/Off)

Range = 40 to 330 A DC

Percentage Of Range = 50%

Min = 40 A DC

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

Set

Panel/Remote

Switch

Set Remote

Process

Set Range

Set Control

Max (185 A DC)

Min (40 A DC)

Adjust Optional Remote Control

0774 / Ref. 217 356-A / 803 231

OM-4409 Page 35

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. 120 Volt And 240 Volt Receptacles

1

3

4

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 30 A AC Twistlock

Receptacle RC1

Receptacles supply 60 Hz single­phase power at weld/power speed.

2

If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.

 At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
is working properly.

3 Supplementary Protector CB1
4 Supplementary Protector CB2
CB1 protects RC1 and the genera-

tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset.

CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset.

 If a supplementary protector

continues to open, contact
Factory Authorized Service
Agent.

 Generator power is not af-

fected by weld output.

Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re­ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:

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

4.0 kVA/kW

OM-4409 Page 36

191 624

7-2. Connecting To Optional AC Power Plant

Single-Phase Power Connection

Three-Phase Power Connection

Remove plug
before inserting
leads. Reinstall
bushing.

5

6

7

9

8

! Close panel opening

120V

12

if no connections are
made to power plant.

Rear Of Panel

91 92 93

240V

120V

240V

240V

1-Phase

240V

3-Phase

AC
Output

Volts

Amps

KVA/KW

Engine Speed 1850 RPM

Lead 42 connects to GROUND stud on
front of unit.

Jumper 42 is connected to 90 at factory.

! Close panel

Single
Phase

1

120/240

50
12

60 HzFrequency

4

3

2

12

10

11

opening if no
connections
are made to
power plant.

Tools Needed:

Three

Phase

3

240

48
20

 Do not weld while using optional ac

power plant.

 Place Process/Contactor switch in

Weld Terminals Always On - Stick
position when using optional ac
power plant (see Section 6-3).

Single-Phase Generator Power

1 120/240 V 50 A Receptacle RC5
RC5 is connected to the optional ac

power plant and supplies 60 Hz single­phase power at weld/power speed.
Maximum output from RC5 is 12 kVA/
kW. Power available at RC5 is reduced
when welding.

2 Supplementary Protector CB7
Supplementary protector CB7 protects

single-phase receptacle RC5 and the
load wires from overload. If CB7
opens, all generator ac output stops
and the receptacle does not work.

Three-Phase Generator Power

! Stop engine.
! Power and weld outputs are live

at the same time. Disconnect or
insulate unused cables.

 Have qualified person install ac-

cording to circuit diagram and
Generator Power Guidelines (see
Section 16).

Remove power panel mounting

93

screws. Tilt panel forward.
3 Lead 93

91

4 Lead 92

90

5 Lead 91
6 Lead 42 (Circuit Grounding Lead)

92

7 Lead 90 (Neutral)
8 Isolated Neutral Terminal
9 Jumper Lead 42
10 Grounding Terminal
Jumper 42 is connected to lead 90 at

factory. Jumper 42 may be discon­nected from neutral to meet applicable
electrical codes.

Lead 42 connects to front panel
Ground stud.

11 User-Supplied Leads
12 Supplementary Protector CB7

User Terminals

Connect user-supplied leads to termi­nals on CB7 and to the isolated neutral
terminal and grounding terminal as
necessary.

 Supplementary protector CB7 pro-

tects single-phase receptacle RC5
and the load wires from overload.
If CB7 opens, all ac power plant
output stops and the receptacle
does not work.

Reinstall power panel.

Ref. 197 399 / 802 332-B

OM-4409 Page 37

7-3. Optional Generator Power Receptacles

European Receptacle

5

6

Australian Receptacle

5

6

South African Receptacle

5

6

1

1 120 V 20 A AC GFCI

Receptacle GFCI1

2 240 V 16 A AC European

Receptacle RC1

2

3 240 V 15 A AC Australian

Receptacle RC1

4 240 V 15 A AC South African

Receptacle RC1

Receptacles supply 60 Hz single­phase power at weld/power speed.

If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.

 At least once a month, run en-

gine at weld/power speed and
press test button to verify GFCI
is working properly.

31

5 Supplementary Protector CB2
6 Supplementary Protector CB3
CB2 protects GFCI1 from overload.

If CB2 opens, GFCI1 does not
work. Place button to reset breaker.

CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.

 If a supplementary protector

continues to open, contact
Factory Authorized Service
Agent.

 Generator power is not af-

fected by weld output.

41

Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re­ceptacles is 4 kVA/kW.

EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:

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

4.0 kVA/kW

OM-4409 Page 38

191 624

SECTION 8 − OPERATING OPTIONAL BATTERY CHARGER

8-1. Battery Charge Controls

1 Output Selector Switch

NOTICE − Do not switch under load. Stop en-
gine or set Process/Contactor switch to any
Remote position before switching.

Use switch to select weld or battery charge

1

output. Output automatically decreases (but
does not stop) when terminal voltage is 15 to
25 percent above required battery voltage.

 Before connecting charging cables, place

Output Selector switch in position match­ing voltage of battery being charged.

When done charging, stop engine or set Pro­cess/Contactor switch to any Remote On/Off
Switch Required position. Move Output Selec­tor switch to AC Weld or DC Weld position.

8-2. Determining Battery Charging Current

400

350

300

250

200

150

100

50

BATTERY CHARGING CURRENT (AMPS)

0

0

BATTERY COLD CRANK AMP RATING (CCA)

500 1000 1500 2000

803 231-A / 210 149-B

1

1 Battery Charging Current

Chart

Find battery cold crank amp (CCA)
rating on battery. Use CCA rating
on chart to find charge current set­ting for battery.

EXAMPLE: If battery CCA rating is
500, charging current from chart is
100 amperes.

Do not exceed charging current
found on chart. For longer battery
life, use lowest charge rate
possible.

142 975-B

OM-4409 Page 39

8-3. Battery Charge Cable Connections

1

! Stop engine.

! Do not charge or jump start a battery

which has loose terminals or one
showing damage such as a cracked
case or cover.

! Have only qualified persons do bat-

tery charging work.

! Keep cables away from moving

parts.

! Do not use damaged cables.

! Be sure charger output voltage

matches battery voltage.

4

+

3

2

−

! Read BCI Battery Service Manual

before charging or jump starting.

 Before connecting to battery, place

Output Selector switch in position
matching voltage of battery being
charged.

1 Battery

2 Battery Charging Cables

For battery charging, use less than 20 feet
(6.1 m) of AWG #1 or larger cable. For jump
starting, use less than 20 feet (6.1 m) of
AWG 2/0 or larger cable.

3 Terminal Lug

5

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

Use lugs of proper amperage capacity and
hole size for connecting to charge output
terminals.

Install suitable connectors on remaining
ends of battery cables.

4 Battery Charge Positive (+) Output

Terminal

5 Battery Charge Negative (−) Output

Terminal

 Connect charging cables to battery

charge output terminals before con­necting to battery terminals.

Connect Battery Charge Positive (+) cable
to battery positive (+) terminal, and battery
Charge Negative (−) cable to battery nega­tive (−) terminal.

OM-4409 Page 40

8-4. Battery Charging Procedure

In Example:
Battery Voltage = 12 Volts
Battery CCA Rating = 500
Charge Current = 100 A (See Section 8-2)
Ampere Range Setting = 55 to 125 A
V/A Control Setting = Any Position

 This battery charging procedure uses

the front panel controls to turn charging
output on and off.

Stop Engine.

Determine Charge Current From

Battery CCA Rating And Chart

(See Section 8-2).

Set Process/Contactor Switch To

Any Remote On/Off Switch Required

Position.

Set Ampere Range Switch To Lowest

Range That Exceeds Charge Current.

NOTICE − Do not switch under load.

Set Output Selector Switch To

Voltage Of Battery Being

Charged (12 Or 24 Volt).

NOTICE − Do not switch under load.

−

+

Connect Cables (Observe

Correct Polarity).

Start Engine.

Set Process/Contactor Switch

To Any Weld Terminals Always On

Position To Begin Charging.

 To control battery charging output using a

remote device connected to the Remote
14 receptacle, keep Process/Contactor
switch in Remote On/Off Switch Required
position and use remote device to turn
charging output on and off.

Charge 10 minutes. Check

Battery Voltage. Continue

Charging If Necessary.

OM-4409 Page 41

8-5. Jump Starting Procedure

 Charge battery for 10 minutes before

jump starting battery.

Stop Engine.

Set Ampere Range Switch To

300-Max Position.

NOTICE − Do not switch under load.

Set Process/Contactor Switch To

Any Remote On/Off Switch Required

Position.

−

+

Connect Cables (Observe

Correct Polarity).

Set Output Selector Switch To

Voltage Of Battery Being

Charged (12 Or 24 Volt).

NOTICE − Do not switch under load.

Connect Remote

OR

Control Device

(Momentary-On

Switch).

Start Engine.

OM-4409 Page 42

Press (Close) Remote Momentary-On

Switch While Cranking Engine Of Equip-

ment Being Jump Started. Release Switch

When Equipment Starts. Stop Welding

Generator And Disconnect Cables.

Press (close)
switch only while
cranking engine of
equipment being
started.

Stop Engine.

Disconnect

Cables.

SECTION 9 − ENGINE/GENERATOR MAINTENANCE

9-1. Engine Maintenance Label

OM-4409 Page 43

9-2. Routine Engine/Generator Maintenance

 See Section 10 for air compressor maintenance information.

Recycle engine

fluids.

! Stop engine before maintaining.

 See Engine Manual and Maintenance Label

for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.

Every

8

Hours

Every

50

Hours

Every

100

Hours

Every

250

Hours

Every

500

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

FUEL

WATER

 Fuel/Water Separator  Fuel Level  Oil Level  Oil, Fuel Spills

 Weld Terminals

 Battery Terminals  Air Cleaner Hoses  Air Cleaner Element

1/2 in.

(13 mm)

 Unreadable Labels  Fan Belt Tension  Cooling System Spark Arrestor

Reference

Section 5-7,
9-6

Section 9-4

Engine
Manual,
Section 9-5

Every

1000

Hours

Every

3000

Hours

Every

6000

Hours
or 5
Years

 Weld Cables  Oil  Oil Filter

OR

SLUDGE

 Fuel Filter  Inside Unit Valve Clearance*  Drain Sludge

 Slip Rings*
 Brushes*

 Injectors*

 Engine Timing Belt

FUEL

Section 9-6,
9-3 and
Engine
Manual

OM-4409 Page 44

9-3. Checking Generator Brushes

Damaged Brushes

! Stop engine and let cool.

1 Generator Brush
Remove brushes from brush holder.
Replace brushes if damaged or if brush

material is at or near minimum length.

Minimum Length:

5/8 in (16 mm)

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

Replace

1

Ref. 206 467

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)

18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4409 Page 45

9-4. Servicing Engine Air Cleaner

3

Optional

Keep nozzle
2 in (51 mm)

from element.

! Stop engine.

NOTICE − Do not run engine without air
cleaner or with dirty element. Engine
damage caused by using a damaged ele­ment is not covered by the warranty.

1 Engine Air Cleaner

 The air cleaner primary element can

be cleaned but the dirt holding capac­ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean­ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele­ment.

If you decide to clean the primary ele­ment, we strongly recommend instal-

1

52 4

6

ling an optional safety element to pro­vide additional engine protection.
Never clean a safety element. Re­place the safety element after servic­ing the primary element three times.

Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re­place primary element yearly or after six
cleanings.

2 Housing
3 Safety Element (Optional)
4 Primary Element
5 Dust Cap
6 Dust Ejector

To clean air filter:

Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele­ment if it has holes or damaged gaskets.

Reinstall primary element and cap (dust
ejector down).

OM-4409 Page 46

Blow Inspect

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

9-5. Inspecting/Cleaning Optional Spark Arrestor Muffler

2

1

! Stop engine and let cool.

1 Spark Arrestor Muffler
2 Cleanout Plug
Remove plug and remove any dirt

covering cleanout hole.
Start engine and run at idle speed to

blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.

! Stop engine and let cool.

Reinstall cleanout plug.

Tools Needed:

3/8 in

803 228 / 803 230

OM-4409 Page 47

9-6. Adjusting Engine Speed

! Stop engine and let cool.

Engine speed is factory set and
should not require adjustment. Af­ter tuning engine, check engine no
load speed with a tachometer or fre­quency meter (see table for no load
speeds). If necessary, adjust speed
as follows:

Start engine and run until warm.
Turn Process/Contactor switch to

Weld Terminals Always On − Stick
position.

1 Throttle Rod
2 Locknut
Loosen locknuts. Place engine

control switch in Run/Idle position.
Wait 15 seconds for throttle sole-

noid to energize and lower engine
speed to idle rpm.

Turn throttle rod to adjust idle
speed. Tighten locknuts.

3 Engine Speed Adjustment

Screw
4 Locknut
Place engine control switch in Run

position.
Loosen locknut. Turn screw to ad-

just weld/power speed. Tighten
locknut.

 Do not set engine speed higher

than specified.

! Stop engine.

Close door.

Tools Needed:

OM-4409 Page 48

3/8, 7/16 in

2

1

2

3

4

1850 rpm Max.
(61.6 Hz)

1235 rpm
(41.1 Hz)

803 228 / 802 313-A

9-7. Servicing Engine Fuel And Lubrication Systems

Tools Needed:

3

1

4

5

7

6

Right Side

2

! Stop engine and let cool.
! After servicing, start engine and

check for fuel leaks. Stop engine,
tighten connections as necessary,
and wipe up spilled fuel.

1 Oil Filter
2 Oil Drain Hose And Valve
3 Oil Fill Cap
4 Primary Fuel Filter (Fuel/Water

Separator)
5 Petcock
6 Secondary Fuel Filter
7 Fuel Tank Sludge Drain Valve

To change oil and filter:

 The engine oil drain and compressor oil

drain hoses are located together in the

base. Be sure to select the correct hose
when draining engine oil.

Route engine oil drain hose through hole in
base. See engine manual and engine main­tenance label for oil specifications.

To drain water from fuel system:

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

To replace primary fuel filter:

Turn filter counterclockwise. Remove filter.
Apply thin coat of fuel to gasket on new filter.

Fill filter with fuel. Install filter and turn clock­wise until tight. Bleed air from fuel system
according to engine manual.

Inspect fuel lines, and replace if cracked or
worn.

To replace secondary fuel filter:

See engine manual.
Close doors.

To drain sludge from fuel tank:

803 228

! Beware of fire. Do not smoke and

keep sparks and flames away from
drained fuel. Dispose of drained fuel
in an environmentally-safe manner.
Do not leave unit unattended while
draining fuel tank.

! Properly lift unit and secure in a level

position. Use adequate blocks or
stands to support unit while drain­ing fuel tank.

Attach 1/2 ID hose to drain valve. Put metal
container under drain, and use screwdriver
to open sludge drain valve. Close valve
when sludge has drained. Remove hose.

OM-4409 Page 49

9-8. Engine/Generator Overload Protection

9

4

5

! Stop engine.

 When a supplementary protector,

circuit breaker or fuse opens, it
usually indicates a more serious
problem exists. Contact Factory
Authorized Service Agent.

 See Section 10-4 for air compres-

sor overload protection.

1 Fuse F1
2 Fuse F2
F1 and F2 protect the stator exciter

winding from overload. If F1 opens,
weld and generator power is low or
stops entirely. If F2 opens, weld output
is low or stops entirely. 4 kVA/kW gen­erator power is still available.

3 Circuit Breaker CB4 (Not Shown)
4 Supplementary Protector CB5
5 Supplementary Protector CB6
6 Circuit Breaker CB10 (Not

Shown)
7 Supplementary Protector CB11
8 Supplementary Protector CB12

21

8

7

9 Supplementary Protector CB13
10 Circuit Breaker CB14

(Not Shown)
CB4 protects the welding arc drive (dig)

circuit. If CB4 opens, electrode may
stick to the workpiece more frequently
during low voltage (short arc length)
conditions. CB4 automatically resets
when the fault is corrected.

CB5 protects the 24 volt ac output to re­mote receptacle RC14, and 24 volt out­put to field current regulator board PC1.
If CB5 opens, weld output and 24 volt
output to RC14 stops. On units with op­tional power plant, power at receptacle
RC5 also stops if CB5 opens.

CB6 protects the 115 volt ac output to
remote receptacle RC14. If CB6 opens,
115 volt output to RC14 stops.

CB10 protects the engine battery cir­cuit. If CB10 opens, the engine will not
crank. CB10 automatically resets when
the fault is corrected.

CB11 protects the engine wiring har­ness. If CB11 opens, weld output stops
(generator power is still available).

CB12 protects the field flashing circuit.
If CB12 opens, the generator may not
excite at start-up and weld and genera­tor power output may not be available.

CB13 protects the engine shutdown cir­cuit. If CB13 opens, the engine cranks
but does not start.

Press button to reset.
CB14 protects the throttle solenoid. If

CB14 opens, the engine will not run at
idle speed. CB14 automatically resets
when the fault is corrected.

OM-4409 Page 50

803 229

SECTION 10 − AIR COMPRESSOR MAINTENANCE

 Use only genuine Ingersoll Rand compressor oil and filters to maintain 3-year warranty on air compressor. The air compressor warranty will be

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

The air compressor normally requires service at the intervals listed in the maintenance schedule if used in a clean, dry environment. The compres­sor will require service more often if used in dirty, humid conditions.

10-1. Air Compressor Maintenance Label

OM-4409 Page 51

10-2. Routine Air Compressor Maintenance

 See Section 9 for engine/generator maintenance information.

Recycle air

compressor

fluids.

! Stop engine before maintaining.

 See Compressor Maintenance Label for im-

portant start-up, service, and storage infor­mation. Service air compressor more often
if used in severe conditions.

Every

8

Hours

Every

100

Hours

Every

250

Hours

Every

500

Hours

 = Check  = Change  = Clean  = Replace
* To be done by Factory Authorized Service Agent

 Spills  Oil Level

 Air Cleaner Hoses

 Unreadable Labels  Belt Tension  Cooling System Air Filter Element

 Worn or Damaged Air/Oil

Hoses

Reference

Section 5-7

Section
10-3

Section
10-5

 Oil  Oil Filter

Every

1000

Hours

 Air/Oil Separator

OM-4409 Page 52

Section
10-5

10-3. Servicing Compressor Air Cleaner

3

Keep nozzle
2 in (51 mm)

from element.

! Stop engine.

NOTICE − Do not run air compressor
without air cleaner or with dirty element.
Compressor damage caused by using a
damaged element is not covered by the
warranty.

1 Compressor Air Cleaner

 Remove engine air cleaner cover

and element to access compressor
air cleaner (see Section 9-4)

 The air cleaner primary element can

be cleaned but the dirt holding capac­ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean­ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-

1

52 4

6

ment.

If you decide to clean the primary ele­ment, we strongly recommend instal­ling an optional safety element to pro­vide additional air compressor
protection. Never clean a safety ele-
ment. Replace the safety element af­ter servicing the primary element
three times.

Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re­place primary element yearly or after six
cleanings.

2 Housing
3 Safety Element
4 Primary Element
5 Cover
6 Dust Ejector

To clean air filter:

Wipe off cover and housing. Remove
cover and dump out dust. Remove ele­ment(s). Wipe dust from inside cover and
housing with damp cloth. Reinstall safety
element (if present). Reinstall cover.

NOTICE − Do not clean housing with air
hose.

Clean primary element with compressed
air only.

Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele­ment if it has holes or damaged gaskets.

Reinstall primary element and cover
(dust ejector down).

Blow Inspect

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

OM-4409 Page 53

10-4. Compressor Overload Protection

! Stop engine.

 When a circuit breaker or fuse

opens, it usually indicates a more

serious problem exists. Contact

Factory Authorized Service Agent.

 See Section 9-8 for engine/genera-

tor overload protection.

1 Circuit Breaker CB15
Circuit breaker CB15 protects the air

compressor clutch. If CB15 opens, the
compressor does not run and air output
stops.

Press button to reset breaker.

OM-4409 Page 54

1

803 228 / 803 229

10-5. Servicing Air Compressor

Tools Needed:

7/8, 15/16 in

4

5

Right Side

! Stop engine and let cool. Wait 20 sec-

onds for system pressure to drop be­fore changing oil.

1 Air Compressor Oil Filter

2 Air Compressor Air/Oil Separator

3 Air Compressor Oil Drain Hose

w/Removable Cap

4 Air Compressor Oil Fill Cap

5 Air Compressor Oil Level Indicator (On

Tank)

6 Oil Scavenge Tube

2

To change compressor oil and filter:

 The engine oil drain and compressor oil

drain hoses are located together in the
base. Be sure to select the correct hose
when draining compressor oil.

 Be sure o-rings at oil drain and oil fill fit-

tings are in place before reinstalling caps.

Drain compressor oil while compressor is still
warm.

Route compressor oil drain hose through hole
in base. Remove compressor oil fill cap. Re­move cap from oil drain hose and drain oil into
a suitable container. Reinstall oil drain hose
cap. Tighten cap with wrench.

Remove filter by turning filter counterclock­wise. Remove filter. Apply thin coat of oil to
gasket on new filter. Install new filter and turn
clockwise until tight.

To o

High

Full

1

6

3

Add recommended oil until oil level indicator
shows system is full (see compressor mainte­nance label for oil specifications). Reinstall oil
fill cap. Tighten cap with wrench.

To replace air/oil separator:

Loosen nut securing tube on separator base.
Lift oil scavenge tube from separator. Turn fil­ter counterclockwise. Remove filter.

Apply thin coat of oil to gasket on new filter.
Install filter and turn clockwise. Reinstall oil
scavenge tube.

Start engine, run air compressor, and check
for oil leaks.

To o

Low

803 228

! Stop engine.

OM-4409 Page 55

10-6. Adjusting Compressor Air Pressure

Tools Needed:

5/16, 3/8 in

Check compressor air pressure using
air pressure gauge known to be accu­rate. If necessary, adjust air pressure
as follows:

1 Screw
Loosen jam nut securing screw. Turn

screw clockwise (increase pressure)
or counterclockwise (decrease) until
pressure is 125 psi (862 kPa).

 Maximum weld output is reduced

if compressor air pressure is set
above 125 psi (862 kPa).

Tighten nut.
2 Pressure Relief Valve
Pressure relief valve opens and re-

leases pressure at 150 psi (1034
kPa). The pressure relief valve is not
adjustable.

OM-4409 Page 56

1

2

803 228

SECTION 11 − TROUBLESHOOTING

11-1. Troubleshooting Tables

A. Welding

Trouble Remedy

No weld output; generator power output
okay at ac receptacles.

No weld output or generator power
output.

Erratic weld output. Check and tighten connections inside and outside unit.

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

Voltage/Amperage control does not
work when welding in Stick mode.

Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
On/Off Switch Required position and connect remote contactor to Remote 14 receptacle RC14 (see Sec­tions 5-10 and 6-1).

Check position of Ampere Range switch.

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

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

Reset supplementary protector CB5 (see Section 9-8). Check for faulty remote device connected to
RC14.

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

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

Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check
brushes and slip rings, field excitation circuit, field current regulator board PC1, and the rotor.

Disconnect equipment from generator power receptacles during start-up.

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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

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

Be sure connection to work piece is clean and tight.

Use dry, properly stored electrodes.

Remove excessive coils from weld cables.

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

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

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

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

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

Electrode sticks to the workpiece more
frequently during low voltage (short arc
length) conditions.

Low open-circuit voltage. Check engine weld/power speed, and adjust if necessary.

No remote fine amperage or voltage
control.

Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.

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

Place Panel/Remote Switch in Remote position.

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

Repair or replace remote control device.

OM-4409 Page 57

Trouble Remedy

Constant speed wire feeder does not
work.

Low CV weld output. Set Ampere Range switch to highest range.

Min or max CV weld output only. Check position of Voltage/Amperage Adjust control and Panel/Remote Switch.

Reset supplementary protector(s) CB5 and CB13 (see Section 9-8).

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

Repair or replace wire feeder.

Repair or replace remote control device.

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

B. Standard Generator Power

Trouble Remedy

No generator power output at ac recep­tacles; weld output okay.

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

High output at generator power
receptacles.

Reset receptacle supplementary protectors.

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.

Reset supplementary protector CB12. Have Factory Authorized Service Agent check field current regula­tor board PC1 (see Section 10-4).

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

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

Low output at generator power
receptacles.

C. Optional AC Power Plant

Trouble Remedy

No or low output at optional ac power
plant/receptacle RC5.

High output at optional ac power plant/
receptacle RC5.

Erratic output at optional ac power plant/
receptacle RC5.

Have Factory Authorized Service Agent adjust field current resistor R3.

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

Check fuse F1, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte­grated rectifier SR1, resistor R3, and capacitor C9.

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

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

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

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

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

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

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

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

OM-4409 Page 58

D. Engine

Trouble Remedy

Engine will not crank. Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8).
Have Factory Authorized Service Agent check engine wiring harness and components.

Check engine wiring harness plug connections.

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

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, and diode/
capacitor board D8/C8.

Engine cranks but does not start. Check fuel level. Optional low fuel shutdown stops engine if fuel level is low.

Reset supplementary protector CB13 (see Section 10-4 ). Have Factory Authorized Service Agent check
engine wiring harness and components.

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

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.

Air in fuel system. See engine manual.

Engine starts, but stops when Engine
Control switch is released.

Engine hard to start in cold weather. Use starting aid switch (see Section 6-1). If Starting Aid switch does not work have Factory Authorized

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

Engine slowly stopped and cannot be
restarted.

Battery discharges between uses. Turn Engine Control switch S1 off when unit is not running.

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-7).

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

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

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

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

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

Check oil level. Automatic shutdown system stops engine if oil pressure is too low or engine temperature
is too high (see Section 5-7).

Have Factory Authorized Service Agent check time delay relay TD1, control relay CR5, fuel pump,
and fuel solenoid FS1.

See engine manual.

Check fuel level.

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

See engine manual.

Engine idles, but does not come up to
weld speed.

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

Recharge or replace battery if necessary.

Periodically recharge battery (approximately every 3 months).

Have Factory Authorized Service Agent check idle module PC7.

Check for obstructed throttle solenoid.

OM-4409 Page 59

Trouble Remedy

Engine does not run at idle speed. Turn Process/Contactor switch to any position but Remote On/Off Switch Required-TIG.

Check for obstructed throttle solenoid.

Allow circuit breaker CB14 to reset. Have Factory Authorized Service Agent check throttle solenoid TS1
and linkage (see Section 9-8).

Have Factory Authorized Service Agent check idle module PC7, control relays CR3 and CR6, and current
transformer CT1.

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

Dry engine (see Section 14).

E. Air Compressor

Trouble Remedy

Air compressor does not operate; no air
pressure at air shutoff valve.

Air compressor stops after short period
of operation.

Low air pressure. Check for leaks in air lines and hoses.

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

Pneumatic tools freeze up because of
moisture in compressed air.

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

Oil in compressor air cleaner. Have Factory Authorized Service Agent verify compressor inlet valve is operating properly.

Place Air Compressor switch in On position. The air compressor will not start if still under pressure. If
compressor is turned off, wait for air pressure to bleed off (about 20 seconds) before turning compressor
on again.

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

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

Have Factory Authorized Service Agent check Air Compressor switch S10, control relay CR10, air pres­sure switch S11, temperature switch S12, compressor control circuit, and air compressor clutch.

Check compressor oil level (see Section 5-7). Automatic shutdown stops compressor if compressor tem­perature is too high.

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

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

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

Have Factory Authorized Service Agent check compressor for rated output.

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

Install optional air dryer/filter kit (Part No. 195 117).

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

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

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

F. Optional Battery Charging

Trouble Remedy

No battery charge output; weld output
okay.

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

OM-4409 Page 60

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

Check and tighten battery connections if necessary.

Turn on remote control device or turn Process/Contactor switch to any Weld Terminals Always On
position (see Section 6-3).

Check fuses F1 and F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.

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

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

SECTION 12 − AIR COMPRESSOR DIAGRAM

Figure 12-1. Circuit Diagram For Air Compressor

209 059-A

OM-4409 Page 61

SECTION 13 − CIRCUIT DIAGRAM

OM-4409 Page 62

Figure 13-1. Circuit Diagram For Welding Generator

221 915−C

OM-4409 Page 63

14-1. Wetstacking

1

SECTION 14 − RUN-IN PROCEDURE

NOTICE − Do not perform run-in
procedure at less than 20 volts
weld output and do not exceed duty
cycle or equipment damage may
occur.

1 Welding Generator

2

Run diesel engines near rated volt­age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name­plate, rating label, or specifications
section in this manual to find rated
voltage and current.

NOTICE − Do not idle engine longer
than necessary. Piston rings seat
faster if engine runs at weld/power
rpm, and the welding generator is
kept loaded during run-in.

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_in1 2007−04

OM-4409 Page 64

14-2. Run-In Procedure Using Load Bank

4

2

3

! Stop engine.
! Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

! Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in
procedure at less than 20 volts weld

1

output and do not exceed duty
cycle or equipment damage may
occur.

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
Place A/V range switch in maxi-

mum position, A/V control in mini­mum position, and Output Selector
switch (if present) in either DC
position.

3 Weld Cables
Connect load bank to generator

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

Start engine and run for several
minutes.

Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name­plate, rating label, or the specifi­cations section in this manual).

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

NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.

It is recommended to run the weld­ing generator for two hours mini­mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.

! Stop engine and let cool.

4 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

S-0683

OM-4409 Page 65

14-3. Run-In Procedure Using Resistance Grid

6

2

3

4

+

5

! Stop engine.
! Do not touch hot exhaust

pipe, engine parts, or load
bank/grid.

! Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in
procedure at less than 20 volts weld
output and do not exceed duty
cycle or equipment damage may
occur.

1 Resistance Grid

1

Use grid sized for generator rated
output.

Turn Off grid.
2 Welding Generator

Place A/V range switch in maxi­mum position, A/V control in mini­mum position, and Output Selector
switch (if present) in either DC
position.

3 Weld Cables
Connect grid to generator weld

output terminals using proper size
weld cables with correct connec­tors (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 A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).

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

NOTICE − Check oil level frequent-
ly during run-in; add oil if needed.

It is recommended to run the weld­ing generator for two hours mini­mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.

! Stop engine and let cool.

6 Engine Exhaust Pipe
Repeat procedure if wetstacking is

present.

OM-4409 Page 66

S-0684

SECTION 15 − AIR COMPRESSOR TABLES

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

Gauge Pressure (psi)

1 0.027 0.107 0.242 0.430 0.97 1.72 3.86 6.85
2 0.038 0.153 0.342 0.607 1.36 2.43 5.42 9.74
3 0.046 0.188 0.471 0.750 1.68 2.98 6.71 11.9
5 0.059 0.242 0.545 0.965 2.18 3.86 8.71 15.4

10 0.084 0.342 0.77 1.36 3.08 5.45 12.3 21.8

15 0.103 0.418 0.94 1.67 3.75 6.65 15.0 26.7
20 0.119 0.485 1.07 1.93 4.25 7.7 17.1 30.8
25 0.133 0.54 1.21 2.16 4.75 8.6 19.4 34.5
30 0.156 0.632 1.40 2.52 5.6 10.0 22.5 40.0
35 0.173 0.71 1.56 2.80 6.2 11.2 25.0 44.7

40 0.19 0.77 1.71 3.07 6.8 12.3 27.3 49.1
45 0.208 0.843 1.9 3.36 7.6 13.4 30.3 53.8
50 0.225 9.14 2.05 3.64 8.2 14.5 32.8 58.2
60 0.26 1.05 2.35 4.2 9.4 16.8 37.5 67.0
70 0.295 1.19 2.68 4.76 10.7 19.0 43.0 76.0

80 0.33 1.33 2.97 5.32 11.9 21.2 47.5 85.0

90 0.364 1.47 3.28 5.87 13.1 23.5 52.5 94.0
100 0.40 1.61 3.66 6.45 14.5 25.8 58.3 103.0
110 0.43 1.76 3.95 7.00 15.7 28.0 63.0 112.0
120 0.47 1.90 4.27 7.58 17.0 30.2 68.0 121.0

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

1/64 1/32 3/64 1/16 3/32 1/8 3/16 1/4

130 0.50 2.04 4.57 8.13 18.2 32.4 73.0 130.0
140 0.54 2.17 4.87 8.68 19.5 34.5 78.0 138.0
150 0.57 2.33 5.2 9.20 20.7 36.7 83.0 147.0
175 0.66 2.65 5.94 10.6 23.8 42.1 95.0 169.0
200 0.76 3.07 6.90 12.2 27.5 48.7 110.0 195.0

OM-4409 Page 67

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

70-90 P.S.I.G.

MISCELLANEOUS
PORTABLE
TOOLS

Drill, 1/18” to 3/8” 3.75 6.25 8.75 25 Burring Tool, Large 3.6 6.0 8.4 24

Drill, 3/8” to 5/16” 5.25 8.75 12.25 35 Rammers, Small 3.9 3.25 9.1 13

Screwdriver,
#2 to #6 Screw 1.8 3.0 4.2 12 Rammers, Medium 5.1 8.5 11.9 34

Screwdriver,
#6 to 5/16” Screw 3.6 6.0 8.4 24 Rammers, Large 6.0 10.0 14.0 40

Tapper, to 3/8” 3.0 5.0 7.0 20 Backfill Tamper 3.75 6.25 8.75 25

Nutsetters, to 3/8” 3.6 6.0 8.4 24 Compression Riveter 0.2 cu. ft. per cycle

Percent Use Factor And

Compressed Air Consumption (CF)

MISCELLANEOUS
PORTABLE
TOOLS

Percent Use Factor And

Compressed Air Consumption (CF)

9 sec 15 sec 21 sec 1 min9 sec 15 sec 21 sec 1 min

Nutsetters, to 3/4” 4.5 7.5 10.5 30 Air Motor,

Impact Wrench, 1/4” 2.25 3.75 5.3 15 Air Motor,

Impact Wrench, 3/8” 3.0 5.0 7.0 20 Air Motor,

Impact Wrench, 5/8” 4.5 7.5 10.5 30

Impact Wrench, 3/4” 5.25 8.75 12.25 35 (Production) 3.0 5.00 7.00 20

Impact Wrench, 1” 6.75 11.25 15.75 45 ,HAMMERS

Impact Wrench, 1-1/4” 8.25 13.75 19.2 55 Scaling Hammer 1.3 3.0 4.2 12

Die Grinder, Small 2.25 3.75 5.3 15 Chipping Hammer 4.5 7.5 10.5 30
Die Grinder, Medium 3.6 6.0 8.4 24

Horizontal Grinder, 2” 3.0 5.0 7.0 20 Light 2.25 3.75 5.25 15

Horizontal Grinder, 4” 9.0 15.0 21.0 60 Riveting Hammer,

Horizontal Grinder, 6” 9.0 15.0 21.0 60

Horizontal Grinder, 8” 12.0 20.0 28.0 80

Vertical Grinders and
Sanders, 5” Pad 5.25 8.75 12.25 35 Chain, Lightweight 4.20 7.0 9.8 28
Vertical Grinders and
Sanders, 7” Pad 9.0 15.0 21.0 60 Chain, Heavy Duty 13.1 21.8 30.5 87

1 Horsepower 3.75 6.3 8.75 25

2 Horsepower 7.5 12.5 17.5 50

3 Horsepower 11.25 18.75 26.3 75

Paint Spray Gun

Riveting Hammer,

Heavy 4.5 7.5 10.5 30

SAWS

Circular, 8” 6.75 11.25 15.75 45

Circular, 12” 9.75 16.25 23.8 65

Vertical Grinders and
Sanders, 9” Pad 10.5 17.5 24.5 70

Burring Toll, Small 2.25 3.75 5.3 15

Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.

Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.

The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)

OM-4409 Page 68

SECTION 16 − GENERATOR POWER GUIDELINES

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

16-1. Selecting Equipment

1 Generator 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 double

1

2

3

OR

insulated symbol and/or word­ing on it.

! Do not use 2-prong plug un-

less equipment is double in­sulated.

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

16-2. Grounding Generator To Truck Or Trailer Frame

1

GND/PE

2

3

! Always ground generator

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

! Also see AWS Safety &

Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.

1 Equipment Grounding

Terminal (On Front Panel)

2 Grounding Cable (Not

Supplied)
3 Metal Vehicle Frame
Connect cable from equipment

ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.

 Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

! Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

! If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4409 Page 69

16-3. Grounding When Supplying Building Systems

1 2

GND/PE

2

3

1 Equipment Grounding

Terminal
2 Grounding Cable
Use #10 AWG or larger insulated

copper wire.
3 Ground Device

 Use ground device as stated in

electrical codes.

! Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

! Also see AWS Safety &

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

16-4. How Much Power Does Equipment Require?

3

2

1

3

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 16-8).

3 Rating Data
Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run­ning power requirement in watts.

4.5 A x 115 V = 520 W
The load applied by the drill is 520

watts.
Example 2: If three 200 watt flood

lamps are used with the drill from Ex­ample 1, add the individual loads to
calculate total load.

(3 x 200W) + 520 W = 1120 W
The total load applied by the three

flood lamps and drill is 1120 watts.

OM-4409 Page 70

S-0623

16-5. 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

16-6. 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-4409 Page 71

16-7. 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-4409 Page 72

16-8. Power Required To Start Motor

Single-Phase Induction Motor Starting Requirements

Motor Start

Code

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

G H J K L M N P

1 Motor Start Code
2 Running Amperage

4
1
3

VOLTS AMPS

CODE 60

HP

AC MOTOR

230 2.5

M

1/4

Hz
PHASE

1

2

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.

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

Starting Amperage

Example: Calculate starting amper­age required for a 230 V, 1/4 HP mo­tor with a motor start code of M.

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

11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2

amperes.

S-0624

16-9. How Much Power Can Generator Supply?

1

2

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-4409 Page 73

16-10. Typical Connections To Supply Standby Power

123

Utility

Electrical

Service

Transfer Switch

5

Essential

Loads

Fused

Disconnect

Switch

(If Required)

4

Welding

Generator

Output

! Have only qualified persons

perform these connections
according to all applicable
codes and safety practices.

! Properly install and ground

this equipment according to
its Owner’s Manual and na­tional, state, and local codes.

 Customer-supplied equipment

is required if generator will sup­ply standby power during
emergencies or power out­ages.

1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load

from electric utility service to the
generator. Transfer load back to
electric utility when service is re­stored.

Install correct switch (customer­supplied). Switch rating must be
same as or greater than the branch
overcurrent protection.

3 Fused Disconnect Switch
Install correct switch (customer-

supplied) if required by electrical
code.

4 Welding Generator Output
Generator output voltage and wir-

ing must be consistent with regular
(utility) system voltage and wiring.

Connect generator with temporary
or permanent wiring suitable for the
installation.

Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low volt­age and frequency.

5 Essential Loads
Generator output may not meet the

electrical requirements of the prem­ises. If generator does not produce
enough output to meet all require­ments, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 16-4).

OM-4409 Page 74

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

Cord Lengths for 120 Volt Loads

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

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

Current

(Amperes)

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 (11)

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

Load (Watts) 4 6 8 10 12 14

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 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

OM-4409 Page 75

SECTION 17 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING

gtaw_Phase_2007−04

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

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

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

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

.040” (1 mm) 25-85 20-80
1/16” (1.6 mm) 50-160 50-150
3/32” (2.4 mm) 135-235 130-250

1/8” (3.2 mm) 250-400 225-360

Pure Tungsten (Green Band)

.040” (1 mm) Pure Tungsten Not Recommended 10-60
1/16” (1.6 mm)
3/32” (2.4 mm) 100-160

1/8” (3.2 mm) 150-210

For DCEN − Argon

Balance Control @ 65% Electrode Negative

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

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

AC − Argon

(For Use With Aluminum)

50-100

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

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

local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor­mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ­mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

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

Radial Grinding

Causes Wandering Arc

Wrong Tungsten Preparation

B. Preparing Tungsten For AC Welding

1

2-1/2 Times

Electrode Diameter

2

4

Ideal Tungsten Preparation − Stable Arc

1 − 1-1/2 Times

Electrode Diameter

2

1 Grinding Wheel
Grind end of tungsten on fine grit, hard

3

abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.

1

2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage

capacity.
4 Straight Ground
Grind lengthwise, not radial.

1 Tungsten Electrode
A pure tungsten is recommended..
2 Balled End
Ball end of tungsten by applying AC amper-

age recommended for a given electrode
diameter (see Section 17-1). Let ball on end
of the tungsten take its own shape.

OM-4409 Page 76

SECTION 18 − GUIDELINES FOR TIG WELDING (GTAW)

18-1. Positioning The Torch

! Grinding the tungsten elec-

trode produces dust and fly­ing sparks which can cause
injury and start fires. Use lo­cal exhaust (forced ventila­tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Tho­rium dust contains low-level
radioactive material. Proper­ly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam­mables away.

1 Workpiece
Make sure workpiece is clean

before welding.
2 Work Clamp
Place as close to the weld as

possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten

according to Section 17.

Guidelines:

The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide ade­quate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.

Tungsten extension is the distance
the tungsten extends out gas cup of
torch.

The tungsten extension should be
no greater than the inside diameter
of the gas cup.

Arc length is the distance from the
tungsten to the workpiece.

10−25°

2

1

10−15°

4

3/16 in

Bottom View Of Gas Cup

90°

5

3

4

5
6

6

1/16 in

gtaw 7/2006

Ref. ST-161 892

OM-4409 Page 77

18-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75°

of pool. Repeat process.

75°

15°

Move torch to front

of pool. Repeat process.

ST-162 002-B

OM-4409 Page 78

18-3. Positioning Torch Tungsten For Various Weld Joints

90°

Butt Weld And Stringer Bead

20°

20°

“T” Joint

70°

70°

Lap Joint

Corner Joint

10°

20°

40°

70°

20°

30°

90°

70°

20°

ST-162 003 / S-0792

OM-4409 Page 79

 Hardware is common and not

available unless listed.

SECTION 19 − PARTS LIST

17

3

18

26

25

27

20

129

19

21

133

23

22

24

28

29

30

31

32

33

34

35

130

123

124

125

126

127

128

2

1

16

15

8

148

147

145

143

7

6

4

5

146 − Figure 19-5

134

135

136

137

141

9

13

11 12

14

10

15

132

131 − Figure 19-2

138

139

140

144 − Figure 19-3

OM-4409 Page 80

142

Figure 19-1. Main Assembly

45

46

47

150

69

71

70

44

43

36

151

38

37

42

122

39

113

41

114

40

115

48

116

117

121

49

52

118

112 − Figure 19-4

119

120

53

50

54

51

55

94

109

57

59

95

56

97

93

92

61

98

58

89

91

88

90

96

87

149

110

111

108

99

62

60

84

85 86

82

100

63

83

104

81

101

64

65

102

77

76

74

103

107

67

105

106

66

68

80

78

79

75

72

73

74

803 324

OM-4409 Page 81

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 19-1. Main Assembly

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Quantity

OM-4409 Page 83

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Quantity

Figure 19-1. Main Assembly (Continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 +189827 Panel, Gen Rh 1

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

OM-4409 Page 84

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Figure 19-1. Main Assembly

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

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

131 Figure 19-2 Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132 189731 Firewall, Bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 203260 Label, Caution Do Not Use Ether 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

134 191448 Cover, Top Front Upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135 206609 Upright, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136 +206606 Box, Valve Ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

137 209682 Label, Air Power Ingersoll−Rand 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138 ♦039047 Terminal, Pwr Output Red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

139 +♦207095 Box, Battery Charge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140 ♦039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141 ♦210156 Label, Battery Charge (Battery Charge +/−)1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142 207096 Cover, Box Front Upright 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

143 209683 Label, Warning Safety Air System 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144 Figure 19-3 Panel, Front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145 CT1 202130 Xfmr, Current Sensing (Auto Idle) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146 Figure 19-5 Main Rectifier Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147 193453 Bracket, Mtg Box Fcr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148 PC1 207397 Module, Field Current Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

149 085963 Spring, Ext .375 Od X .041 Wire X 2.000 (ForSafety Latch) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 105734 Pipe, Muffler Extension Elbow 1.750 OD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151 233088 Label, Danger Using A Generator Indoors Can Kill You In Minutes 1. . . . . . . . . . . . . . . . . . . . . .

049525 Nut, 312−18 U−nut Multi−thread 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

049525 Nut, 312−18 U−nut Multi−thread 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

206468 Kit, Label (Includes Safety And Informational Labels) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦195118 Kit, Lock-Out Vandalism (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦209238 Door, Access Rh W/Om Pocket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦209240 Door, Access Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦209236 Tab, Lockout 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . .

♦209241 Mount, Access Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦209242 Mount, Access Lh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦189975 Hinge, Door Access 180 Deg. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦155146 Sponge, Nprn .060 X 1.000 Wide X 4.000 Sce 41 Close 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

♦Optional

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

OM-4409 Page 85

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803 325-D

Figure 19-2. Control Box Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 19-2. Control Box Assembly − (Figure 19-1 Item 131)

1 F1, F2 085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 046432 Holder, Fuse Mintr .250 X 1.250 Panel Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC9 192224 Circuit Card Assy, Display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 201077 Control Box, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 201078 Control Box, Rh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 HM2 ♦145247 Meter, Hour Air Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 CR3,CR6 090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

9 CR8 197325 Relay, Encl 12vdc Spst 70a 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 CB15 083432 Supplementary Protector, Man Reset 1p 10a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

11 CB8 ♦139266 Supplementary Protector, Man Reset 1p 15a 250vac Frict (Air Dryer) 1. . . . . . . . . . . . . .

12 C8/D8,C10/D10 189701 Diode/Capacitor Board 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CR1 214876 Relay, Encl 6vdc Spst 35a/14vdc 5 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB14 205927 Circuit Breaker, Auto Reset 12vdc 12 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 CB10 190374 Circuit Breaker, Auto Reset 12vdc 40 Amp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 CR5 223710 Relay, Encl12vdc Dpst−no 25a 6pin Flange 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CR14 ♦090104 Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg (Air Dryer) 1. . . . . . . . . . . . . . . . . . .

18 SR1 035704 Rectifier, Integ Bridge 40. Amp 800v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 PC7 195706 Module, Pull To Idle, Two Output, 7 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 C1/D1 189701 Diode/Capacitor Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 C9 087110 Capacitor, Elctlt 240 Uf 200 Vdc Can 1.39 Di 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 177136 Clamp, Capacitor 1.375 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

OM-4409 Page 86

Item

No.

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Part

No.

Description

Figure 19-2. Control Box Assembly (Continued)

23 217823 Label, Layout Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 201079 Cover, Control Box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 CR4, CR10 113247 Relay, Encl 12vdc Dpdt 20a/120vac 8pin Flange Mtg 2. . . . . . . . . . . . . . . . . . . . . . .

26 TD1 214928 Timer, Delay On Make/Break Open 30 Sec 12vdc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CB11,CB12,CB13 139266 Supplementary Protector, Man Reset 1p 15a 250vac Frict 3. . . . . . . . . . . . . . . . .

27

217815 Harness, Engine Deutz Bf4m2011 (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156734 Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

148850 Socket, Relay 5 Pin 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S2 021467 Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term. . . . . . . . . . . . . . . . . . . .

(Located On Front Panel, See Figure 19-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211292 Conn, Body 5 Terminal (For Ignition Switch S1) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211293 Conn, Pack Terminal Position Assurance(Lock) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S10 206624 Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term . . . . . . . . . . . . . . . . . . .

(Located On Front Panel, See Figure 19-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

164617 Clip,Wiring Straight 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

219873 Harness, Control Box, Weld Control LH (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC3 158466 Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC1 135133 Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204737 Cable Tie Mount, Winged Push 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CR15 ♦172015 Time Delay Relay (Air Dryer) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦Optional
*Recommended Spare Parts.

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

OM-4409 Page 87

 Hardware is common and

not available unless listed.

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Figure 19-3. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 19-3. Panel, Front w/Components (Figure 19-1 Item 144)

1 217356 Plate, Screened Ident Control Rating 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 215014 Panel, Engine/Weld Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S3 208278 Switch, Range/Changeover 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

192558 Harness, Range Switch (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC6 148389 Conn, Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R1 193118 Pot, Cp Flat 1t 2. W 1k Ohm Linear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

803 326-A

Quantity

OM-4409 Page 88

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Figure 19-3. Panel, Front w/Components (Continued)

206809 Harness, Weld Control (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 S6 193234 Switch, Rotary 6 Position Gold Contacts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197257 Guard, Circuit Breaker (For S6 − Not Included w/Harness) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S5 011609 Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 193183 Conn, Rect Cinch 18 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196603 Seal, Switch 6 Position Rotary .250 Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG14 141450 Conn, Rect Metrmate 10skt 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

164617 Clip,Wiring Straight 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG10 150316 Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CB5 139266 Supplementary Protector, Man Reset 1p 15a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

CB6 139266 Supplementary Protector, Man Reset 1p 15a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 202209 Spacer, Nylon .221 Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 PC6 192995 Circuit Card Assy, Connector/Receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 S1 212436 Switch, Ignition 4 Position W/Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 S10 206624 Switch, Tgl Sptt 6a 125vac (On)−on−(On) Spd Term (Included In Engine. . . . . . . . . . . . . .

Wiring Harness, See Figure Figure 19-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 S2 021467 Switch,Tgl Spst 3a 250v Off−none−(On) Spd Term (Included In Engine. . . . . . . . . . . . . . .

Wiring Harness, See Figure Figure 19-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 CB1 201083 Supplementary Protector, Man Reset 2p 20a 250vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201553 Clip, Retaining Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201109 Harness, Receptacle Auxillary Power (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 CB2 093996 Supplementary Protector, Man Reset 1p 20a 250vac Frict 1. . . . . . . . . . . . . . . . . . . . . . . . .

15 GFCI1 151981 Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 RC1 147632 Rcpt,Tw Lk Grd 2p3w 30a 250v *L6−30r 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010146 Clamp, Nyl .625 Clamp Dia X.500 Wide .203 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC5 ♦182954 Rcpt, Str 3p4w 50a 125/250v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 ♦025248 Stand-off, Insul .250-20 X 1.2 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 ♦604102 Connector, Clamp Cable 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ♦197527 Guard, Circuit Breaker 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦197363 Terminal, Ring Tng Screw Clamp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 CB7 ♦214926 Supplementary Protector, Man Reset 3p 50a 250vac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 +215347 Panel, Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+♦215363 Panel, Generator Power (Full KVA Option) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT2 ♦197433 Transformer, Current Sensing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 ♦214927 Boot, Circuit Breaker 1 Pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 ♦197508 Plug, Protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 ♦077440 Bushing, Conduit 1 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 601836 Nut, 250−20 .50hex .19h Brs 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010915 Washer, Flat .257idx0.640odx.031t Brs 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163167 Washer, Lock .254idx0.489odx.062t Sst Split.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 GRD 083030 Stud, Brs .250−20 X 1.750 W/Hex Collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 ♦209056 Cover, Receptacle W/Gasket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 190861 Label, Warning Electric Shock And Moving Parts Etc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦197399 Label, Warning 3 Ph Generator Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 209056 Cover, Receptacle 2.250 Dia. Lexan 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 ♦210149 Label, Battery Charge (Switch Position) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦ Label, Polarity/AC Switch Position 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 S12 ♦220491 Switch, Polarity/AC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S13 ♦210217 Switch, Battery Charge Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 201125 Panel, Mtg Terminal Power Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 PC4, PC5 189744 Circuit Card Assembly, HF 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 ♦210206 Bracket, Support Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 039046 Terminal, Pwr Output Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180735 Washer, Output Stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 181169 Spacer, Output Stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 186621 Boot, Generic Output Stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Figure 19-3. Panel, Front w/Components (Continued)

41 ♦059773 Switch, Handle (Polarity/AC Switch) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 ♦010647 Pin (Polarity/AC Switch) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦059773 Handle, Switch (Battery Charging) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦010647 Pin,Spring Cs .156 X 1.250 (Battery Charging) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

43 039047 Terminal, Pwr Output Red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 021385 Boot, Toggle Switch Lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 190323 Boot, Circuit Breaker Clear Hex Nut 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 170391 Conn, Circ Ms Protective Cap Size 20 Nylon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 HM1 210424 Meter, Hour 12−24vdc (Snap−in) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 FUEL 192265 Gauge, Fuel Elec Switch W/O Switchgage Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 BAT 193228 Meter, Volt DC 8 − 18 Scale 2.250 In Black Face 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 AIR 206599 Gauge, Pressure 0−200 Psi Electric Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 TEMP 217084 Gauge, Engine Temperature 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 OIL 217083 Gauge, Engine Oil Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 A1 ♦164873 Meter, Amp AC/DC 0− 500 0−600 Dc Scale 2.5 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 CT3 ♦209274 Xfmr, Current (Meters) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 V1 ♦164874 Meter, Volt AC/DC 0− 100 Scale 2.5 In 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 097922 Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 189161 Handle, Switch Range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 010647 Pin, Spring Cs .156 X 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 097924 Knob, Pointer 1.625 Dia X .250 Id W/Set Screwsplstc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

072590 Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215207 Harness, Unit Weld Control − CV (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG6 114063 Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG8 193184 Conn, Rect Cinch 30 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147992 Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG13 158465 Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

088731 Bushing, Snap−in Nyl .375 Id X .500 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135873 Clip, Conduit Convoluted 1/2 In 6.35mm Mtg Hole 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187654 Seal, Wire Univ 12p/S 3row 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196602 Plug, Cavity 18,30 Position Cinch Connector 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

059712 Clip, Component .437 Dia Mtg Adh Back 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

024103 Blank, Snap−in Nyl .750 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120304 Blank, Snap−in Nyl .250 Mtg Hole Black 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

025234 Plug, Str Grd 2p3w 15a 250v *6−15p 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

♦Optional

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

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

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803 327

Figure 19-4. Generator

Item

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No.

Description

Figure 19-4. Generator (Figure 19-1 Item 112)

1 132053 Screw, 375−16x1.50 Hex Hd−pln Gr5 Pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 183387 Washer, Cone .380idx .860odx.109t Stl Pld 4000lbs 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195911 Endbell, Gen (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 143220 O-Ring 2.859 ID X .139 Cs 70 Duro Viton 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 AUX STATOR 201099 Stator, Exciter/Aux Power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 STATOR +208287 Stator, Weld Assy Complete 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STATOR +♦209220 Stator, Weld Assy Complete (3-Phase Generator Option) 1. . . . . . . . . . . . . . . . . . . . . . . .

7 225120 Label, Warning Moving Parts Can Cause Serious 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 190197 Guard, Generator Wire Mesh 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 172674 Spring, Ext .240 Od X .041 Wire X 3.500 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039207 Baffle, Air Gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 ROTOR 212997 Rotor, Generator (Includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 024617 Ring, Rtng Ext 1.375 Shaft X .050 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 053390 Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210447 Fan, Rotor Assy Generator (Segmented) (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hub, Drive (Not Sold Separately) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 210332 Plate, Flex Hubmount 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 206242 Fan, Rotor Segmented Assy Gen 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 049026 Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 080389 Screw, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 049026 Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 191579 Cover, Starter Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 083883 Washer, Lock .402idx0.709odx.087t Stl Split10mm 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4409 Page 91

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-4. Generator (Continued)

23 172555 Screw, M10−1.5x 50 Hex Hd−pln 8.8 Pld 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 602159 Screw, 312−18x .75 Hexwhd.66d Stl Pld Slffmg Tap−rw 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 604950 Screw, 312−18x2.00 Hex Hd−pln Gr5 Pld 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 139341 Washer, Exciter 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 *190823 Brush, Contact Elect .250 X.500 X 1.250 Grd Ay 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 188560 Clip, Spring 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 189142 Brushholder Assy, Generator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 602242 Washer, Flat .375idx0.875odx.083t Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 602211 Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 604534 Screw, 312−18x1.25 Hex Hd−pln Gr5 Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

♦Optional

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

OM-4409 Page 92

 Hardware is common and

not available unless listed.

1

4

3

2

5

6

7

8

9

802 279-A

Figure 19-5. Main Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-5. Main Rectifier Assembly (Figure 19-1 Item 146)

SR3 215910 Rectifier, environmental (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 188137 Connection Board, Rectifier Ac 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 188517 Bus Bar, Conn Bd 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 188135 Enclosure, Rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 134201 Stand−off Support, Pc Card .312/.375w/Post&lock .43 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 PC3 215755 Circuit Card Assy, Protection 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 188136 Insulator, Heatsink 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 188493 Heat Sink, Rectifier Al 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D3, D5, D7 208334 Diode, Rect 275. A 300v Sp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D2, D4, D6 208335 Diode, Rect 275. A 300v Rp 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-4409 Page 93

 Hardware is common and

not available unless listed.

17

15

11

14

9

13

10

9

2

16

79

28

80

10

40

84

9

51

55

4

82

41

58

56

57

61

59

60

81

83

39

62

63

53

54

13

48
47

43

44

9

50

89

42

86

4

85

19

18

49

21

6

12

11

8

7

6

4

3

20

22

24

25

27

45

46

26

23

5

45

1

32

72

26

33

87
88

71

4

75

76

77

78

9

74

73

31

29

34

38

35

37

36

70

64
65
66

67

68

69

OM-4409 Page 94

803 328−G

Figure 19-6. Air Compressor Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-6. Air Compressor Assembly (Figure 19-1 Item 78)

1 206607 Valve, Ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 210523 Ftg, Flrd Stl Tube End/Female Pipe End 3/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 206939 Tank, Oil Separator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 210248 Hose Assy, Air W/Fittings 3/4 X 35.250 Lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 084999 Ftg, Pipe Brs Elbow St 45 1/4 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 117826 Ftg, Pipe Brs Nipple Close 1/4 Npt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 210053 Valve, Pressure Regulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 071270 Ftg, Pipe Brs Tee St 1/4 Npt 071 269 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 209854 Ftg, Pipe Adapter M 1/4 Npt X 1/4 Line 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 218602 Hose, Nylon Blue 44.000lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 210040 Orifice/Muffler,120 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 151662 Ftg, Pipe Brs Plug Hex .125 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 218601 Hose, Nylon Red 36.000lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 210054 Valve, Automatic Blowdown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 206746 Switch, Pressure 20psi Nc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 602965 Ftg, Pipe Brs Tee 1/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 209635 Hose, Assy w/Fittings 42.360lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 209621 Ftg, Stl Adapter 3/4 Sae−3/4 Jic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 210051 Valve, Check Minimum Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 209767 Ftg, Pipe Stl Connector M 3/4 Sae−npt Adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 206615 Sender, Pressure Oil 0− 200 Psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 073655 Ftg, Pipe Brs Nipple Hex 1/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 206937 Manifold, Air 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 206743 Valve, Safety Relief 150psi 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 209754 Ftg, Pipe Stl Elbow M 45dg 3/4 X (Npt−jic 45dg) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 214685 Hose Assy, Air W/Fittings 3/4 X 21.750 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 209787 Ftg, Pipe Stl Nipple Close 3/4 Npt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 209621 Fitting, Stl Adapter 3/4 SAE − 3/4 JIC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 210058 Gauge, Oil Level Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 Deleted. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 209766 Ftg, Pipe Stl Tee Street 3/4 Npt M−f−f 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 209457 Ftg, Pipe Stl Elbow St 3/4 Npt 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 209638 Hose, Oil W/Fittings 25.670 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 209639 Hose, Oil W/Fittings 26.320 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 210254 Bracket, Mtg Tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 210251 Ftg, Stl Swivel Straight Thread Conn 3/4 O−ring 1

37 210252 Ftg, Stl Bulkhead Branch Tee 3/4 Flare Tube End 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 210250 Hose Assy, Oil W/Fittings 3/4 X 15.500 Lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 209765 Ftg, Pipe Stl Elbow Adapter 90dg 3/4 Sae−jic− 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 208040 Tensioner,Belt w/Pully 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 208428 Idler Pulley 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 225038 Bracket, Mtg Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 206742 Switch, High Air Temperature 248f Nc 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210022 O−ring, High Air Temp Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 211904 Manifold, Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

218558 Screw, M 8−1.2x 50 Hex Hd−pln 8.8 Pld (Manifold Mtg.Screws) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 209641 Hose, Nylon White 32.000lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 209855 Ftg, Pipe Stl Adapter M 1/8 Npt X 1/4 Line 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 015732 Ftg, Pipe Brs Elbow St 45 1/8 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 209852 Ftg, Pipe Stl Adapter M M10 X 1/8 Npt F 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 225005 Brace, Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 084999 Ftg, Pipe Brs Elbow St 45 1/4 NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 176518 Ftg, Pipe Brs Elbow St 1/4 Npt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-4409 Page 95

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 19-5. Air Compressor Assembly (Continued)

53 206698 Plate, Mtg Compressor To Bracket 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 218305 Valve, Inlet Unloader 90dg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210016 Gasket, Unloader Valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 CLUTCH 210055 Clutch, Electro Magnetic 12vdc W/5.75 Dia Pulley 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 218609 Belt, Micro V 21mm X 1485mm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 206800 Pulley, Crankshaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 210001 Airend, Gear−driven W/Tapered Input Shaft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 209853 Ftg, Pipe Stl Adapter M M16 1.5 X 1/2 Jic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 209634 Hose, Tubing Oil Assyw/Fittings 15.860lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 206558 Cooler, Oil Engine/Compressor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 209851 Ftg, Pipe Stl Tube End Cap 3/4 0rfs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 209825 Ftg, Stl Adapter Swivel 12m X Jic−12 F 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 209764 Ftg, Pipe Stl Tee Branch Sae−12 X Jic−12 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 209828 Ftg, Stl Swivel Union Jic−12 F−f 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 209621 Ftg, Stl Adapter 3/4 Sae−3/4 Jic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 210052 Valve,Oil Temperature Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 206744 Thermostat, 170f (w/gasket) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 206745 Filter, Oil 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 209756 Ftg, Pipe Stl Elbow M 90dg 1/2 Jic X 3/4 Sae 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 214686 Ftg, Pipe Stl Elbow 90dg 3/4bspt M X 3/4 Jic M 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 210023 Filter, Separator Assembly (includes) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 206747 Separator, Oil/Air Filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 208029 Bracket, Mtg Filter Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 209646 Tubing, Ssstl .312 Od X.028 W/Ftgs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 209856 Ftg, Stl Adapter Tube End Reducer 04f X 05m 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 210027 Valve, Check/Scavenge Orifice/Screen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 209755 Ftg, Pipe Stl Swivel F 1/4 Npt X 1/4 F Jic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*210056 Oil, Compressor 1gal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 044772 Screw, M12−1.7x 30 Hex Hd−pln 8.8 Pln 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 602216 Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 198447 Screw, M10−1.5x 20 Hex Hd−pln 8.8 Pln 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 602243 Washer, Flat .438idx1.000odx.083t Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 208425 Screw, M10−1.5x 60 Hex Hd

−pln 8.8 Pld Din 931 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 198631 Nut, M10 Hex Lock Nut Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 208426 Screw, M12−1.75x 40 Hex Hd 12pt Flange Screw 12.9 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 602216 Washer, Lock .502idx0.879odx.151t Stl Pld Split.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 214687 Ftg, Pipe Stl 3/4bspp X 3/4 Jic M 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 214920 Seal, Ring Bonded Rbr/Stl .950 Id X 1.380 Od X .100 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 218423 O-Ring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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