OM-228 921G 2009−02 Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Description Engine Driven Welding Generator File: Engine Drive
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Engine Hazards . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Servicing Air Cleaner . . . . . . . . . . . .
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2008−08 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.
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.
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 connecting 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.
HYDRAULIC FLUID can injure or kill. Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied. Relieve pressure before disconnecting or connecting hydraulic lines. Check hydraulic system components and all connections and hoses for damage, leaks, and wear before operating unit.
MOVING PARTS can injure. Keep away from fans, belts and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Keep hands, hair, loose clothing, and tools away from moving parts. Before working on compressed air system, turn off and lockout/ tagout unit, release pressure, and be sure air pressure cannot be accidentally applied. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
H.F. RADIATION 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.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_2008−08fre 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.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. Ne pas toucher à mains nues les parties chaudes. Prévoir une période de refroidissement avant de travailler à l’équipement. Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux. Porteur de simulateur cardiaque ou autre implants 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. Si des BOUTEILLES sont endommagées, elles pourront exploser. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression.
L’utilisation d’un groupe autonome 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. 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.
LIRE LES INSTRUCTIONS. Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. N’utiliser que les pièces de rechange recommandées par le constructeur. Effectuer l’entretien en respectant les manuels d’utilisation, les normes industrielles et les codes nationaux, d’état et locaux. 2-5. Dangers liés à l’air comprimé Un ÉQUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou même la mort.
Le MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de provoquer un incendie ou une explosion. Ne pas découper ou gouger à proximité de produits inflammables. Attention aux risques d’incendie: tenir un extincteur à proximité. LIRE LES INSTRUCTIONS. Lire le manuel d’utilisation avant d’installer, d’utiliser ou d’intervenir sur l’appareil. N’utiliser que les pièces de rechange recommandées par le constructeur.
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.
2-9. 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.
SECTION 3 − DEFINITIONS 3-1.
SECTION 4 − SPECIFICATIONS 4-1.
4-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. A. Stick Mode 100 Ranges 300 − Max 185 − 525 125 − 400 85 − 250 55 − 125 DC VOLTS 80 60 40 20 0 0 100 200 300 400 500 600 DC AMPERES 700 800 900 1000 400 500 600 DC AMPERES 700 800 900 1000 B. MIG Mode 100 DC VOLTS 80 60 MAX 40 MIN 20 0 0 100 200 300 C.
4-4. Fuel Consumption 11.35 10.40 9.46 8.51 7.57 6.62 5.67 4.73 3.78 2.84 1.98 0.95 0.00 US GAL./HR. LITERS/HR. The curve shows typical fuel use under weld or power loads. 3.00 2.75 2.50 2.25 2.00 1.75 1.50 1.25 1.00 0.75 0.50 0.25 0.00 0 100 200 300 400 500 600 DC WELD AMPERES AT 100% DUTY CYCLE 700 208 137 4-5. Duty Cycle And Overheating 100% Duty Cycle At 500 Amperes Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
4-6. Generator Power Curve The AC power curve shows the generator power in amperes available at the 120 and 240 volt receptacles. 150 300 AC VOLTS 125 250 100 200 75 150 50 100 25 50 0 0 0 5 10 15 20 AC AMPERES IN 240V MODE 25 30 0 10 20 30 40 AC AMPERES IN 120V MODE 50 60 193 018 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
4-7. Optional Three-Phase Generator Curves 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. AC VOLTS A. 12 kVA/kW Single-Phase AC Output (No Weld Load) 280 270 260 250 240 230 220 210 200 190 90 180 140 135 130 125 120 115 110 105 100 95 20 0 40 60 80 100 AC AMPERES B.
SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Movement ! Do not move or operate unit where it could tip. ! Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. NOTICE − Do not install unit where air flow is restricted or engine may overheat. OR OR See Section 4-2 for lifting eye rating. See Section 5-2 for mounting information. Location/Airflow Clearance OR 18 in. (460 mm) 18 in. (460 mm) 18 in.
5-2. Mounting Welding Generator ! Supporting The Unit Do not weld on base. Welding on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. Use crosssupports to adequately support unit and prevent damage to base. 2 Mounting Surface: 1 2 OR Cross-Supports Mounting Brackets (Supplied) Mount unit on flat surface or use cross-supports to support base.
5-3. Grounding Generator To Truck Or Trailer Frame 1 ! 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. ! Bed liners, shipping skids, and some running gear 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.
5-5. Using Lifting Eye 1 2 3 1 Lifting Eye Nut Carriage Bolt Raise lifting eye until it snaps in place. Lower lifting eye when not needed. To lock the lifting eye in the upright position, insert a 3/8-16 x 1-1/2 in. carriage bolt through slot in bracket and secure with nut (bolt and nut not supplied). 2 Tools Needed: 3 Lift1 2008−01 804 712 5-6. Installing Exhaust Pipe ! Stop engine and let cool. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel.
5-7. Activating The Dry Charge Battery (If Applicable) ! 3 Always wear a face shield, rubber gloves and protective clothing when working on a battery. Remove battery from unit. 1 2 2 1 3 Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) 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.
5-9. Engine Prestart Checks Remove air bleed screw when filling radiator. See Section 5-10. Check radiator coolant level when fluid is low in recovery tank. Full Full Capacity: w/Overflow Tank 10 qt (9.5 L) Diesel Full Coolant Recovery Tank Full 804 583-A Check all engine 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.
5-10. Adding Coolant To Radiator ! Stop engine and let cool. Check coolant level according to Section 5-9 before starting this procedure. Engine coolant is a mixture of water and ethylene glycol base antifreeze. A solution of 50% antifreeze and 50% water must be used in this engine. Do not use 100% antifreeze or severe damage will occur. If coolant level is below bottom of radiator filler neck, add coolant as follows: 1 1 Radiator Air Bleed Screw 2 Radiator Cap Remove air bleed screw.
5-11. Connecting To Weld Output Terminals Stick and TIG Welding For Stick and TIG welding Direct Current Electrode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right. For Direct Current Electrode Negative (DCEN), reverse cable connections. If equipped with optional Polarity switch or optional Polarity/AC switch, connect electrode holder cable to Electrode (+) terminal on left and work cable to Work (−) terminal on right.
5-12. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft 400 ft (105 m) (120 m) Weld Output Terminals ! ! Stop engine before connecting to weld output terminals.
5-13. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information A 24 volts AC. Protected by supplementary protector CB5. B Contact closure to A completes 24 volt AC contactor control circuit. C Output to remote control:+10 volts DC in MIG or Stick mode; 0 to +10 volts DC in TIG mode. D Remote control circuit common. E DC input command signal: 0 to +10 volts from min. to max. of remote control with Voltage/ Amperage Adjust control at max.
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 (.
SECTION 6 − OPERATING WELDING GENERATOR 6-1.
6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls 1 Start/Preheat Switch Use switch to start engine and operate glow plug for cold weather starting. Engine runs continuously. at weld/power speed Turn switch to Preheat position to operate the glow plug and heat the combustion chambers before cranking engine (see starting instructions following). 2 Engine Shutdown Switch Push switch down to stop engine. To Start: NOTICE − Do not use ether to start engine.
6-3. Process/Contactor Control Switch 1 236 982-A 1 Process/Contactor Control Switch (See Section 6-1 For Location) ! Weld output terminals are energized when Process/Contactor Control switch is in a Weld Terminals Always On position and the engine is running. Section 6-4).
6-4. Remote Voltage/Amperage Control 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-13).
6-5.
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles Generator power is not affected by weld output. 1 3 2 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. 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.
7-2. Connecting To Optional Three-Phase Generator (High KVA Models Only) Place Process/Contactor switch 1 Single-Phase Power Connection in Electrode Hot - Stick position when using three-phase generator (see Section 6-3). 2 Single-Phase Generator Power 1 120/240 V 50 A Receptacle RC5 RC5 is connected to the optional three-phase generator and supplies 60 Hz single-phase power at weld/ power speed. Maximum output from RC5 is 12 kVA/kW. Power available at RC5 is reduced when welding.
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 8-1.
8-2. Routine Maintenance ! 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. = Check = Change = Clean = Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Air Cleaner ! 1 2 3 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. 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.
8-4. Inspecting/Cleaning Optional Spark Arrestor ! Stop engine and let cool. 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 3 3 1 Exhaust Pipe With Rain Cap 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. 2 Tools Needed: 3/8 in. Ref. 228 923-A / 804 582-A 8-5.
8-6. 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 Control switch to Stick − Electrode Hot position. 1 Engine Speed Adjustment Screw 2 Locking Nut Loosen nut. Turn screw until engine runs at weld/power speed. Tighten nut.
8-7. Servicing Fuel And Lubrication Systems Tools Needed: 5 4 3 1 Right Side 2 6 Ref. 800 159-E / Ref. 802 170 / 804 583-B ! ! 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 Valve And Hose 3 Oil Fill Cap 4 Fuel Sedimenter 5 Secondary Fuel Filter 6 Fuel Tank Sludge Drain Valve To change oil and filter: Route oil drain hose and valve through hole in base.
8-8. Servicing Engine Cooling System ! Stop engine and let cool. 1 Radiator Cap 2 RAdiator Air Bleed Screw 3 Radiator Drain Cock Drain engine coolant according to procedure in engine manual. 2 Add engine coolant according to procedure in Section 5-10. Tools Needed: 3/8 in. 1 3 Ref. 804 583-A / Ref.
8-9. Overload Protection ! Stop engine. 1 2 Fuse F1 Fuse F2 F1 and F2 protect the stator exciter winding from overload. If F1 opens, weld and generator power is low or stops entirely. If F2 opens, weld output stops. 4 kVA/kW generator power is still available.
8-10. Troubleshooting Tables A. Welding Trouble Remedy No weld output; generator power output Place Process/Contactor switch S6 in a Weld Terminals Always On position, or place switch in a Weld okay at AC receptacles. Terminals Remotely Controlled position and connect remote contactor to optional Remote 14 receptacle RC14 (see Sections 5-13, 6-3 and 6-4). Check position of Amperage Range switch S3. Check position of optional Polarity/AC Selector switch S13.
Trouble Remedy Repair or replace wire feeder. Low CV weld output. Set Amperage Range switch S3 to highest range. Min or max CV weld output only. Check position of Voltage/Amperage Adjust control R1 and Voltage/Amperage Adjust Control switch S5. Repair or replace remote control device. Have Factory Authorized Service Agent check field current regulator board PC1 and connections. B.
Trouble Remedy Check engine wiring harness plug connections. Have Factory Authorized Service Agent check continuity of Engine Start/Preheat switch S1, and replace if necessary. Engine cranks but does not start. Check fuel level. Check battery and replace if necessary. Check engine charging system according to engine manual.
SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1.
237 497-C OM-228 921 Page 51
SECTION 10 − RUN-IN PROCEDURE run_in1 2007−04 10-1. Wetstacking NOTICE − Do not perform run-in procedure at less than 20 volts weld output and do not exceed duty cycle or equipment damage may occur. 1 2 1 Welding Generator 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.
10-2. Run-In Procedure Using Load Bank 4 2 1 ! 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 Load Bank Turn all load bank switches Off. If needed, connect load bank to 115 volts ac wall receptacle or generator auxiliary power receptacle.
10-3. Run-In Procedure Using Resistance Grid 6 2 ! 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 1 Resistance Grid Use grid sized for generator rated output. Turn Off grid.
SECTION 11 − 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. 11-1. Selecting Equipment 1 2 3 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has double insulated symbol and/or wording on it. 1 ! 2 Do not use 2-prong plug unless equipment is double insulated.
11-3. Grounding When Supplying Building Systems 1 2 1 2 Use #10 AWG or larger insulated copper wire. 3 GND/PE Equipment Grounding Terminal Grounding Cable Ground Device Use ground device as stated in electrical codes. 2 3 ! 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. ST-800 576-B 11-4.
11-5.
11-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec.
11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0 1 2 3 4 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: 4 1 3 AC MOTOR VOLTS 230 AMPS 2.5 CODE M Hz 60 HP 1/4 PHASE 1 2 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.
11-10. Typical Connections To Supply Standby Power 1 2 Utility Electrical Service 4 3 Transfer Switch Fused Disconnect Switch (If Required) 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.
11-11. 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.
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 14 15 16 17 2 13 1 85 82 83 86 87 84 18 88 12 5 3 6 4 19 11 9 10 8 7 90 89 92 91 111 93 112 94 110 12 95 102 96 103 109 (Fig.12−5) 104 101 (Fig.12−2) 91 97 108 98 99 105 107 (Fig.12−3) 100 106 Figure 12-1.
39 36 26 21 27 25 22 23 37 38 33 24 40 35 42 34 31 20 43 30 32 30 41 112 28 44 29 81 78 77 75 74 73 45 76 79 80 61 62 30 56 60 59 58 63 64 65 70 71 49 57 50 113 51 66 52 67 68 69 72 (Fig 12−4) 46 47 48 53 55 54 804 572-D OM-228 921 Page 63
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly . . . 1 . . . . . . . . . . . . . +199294 . . . 2 . . . . . . . . . . . . . +199301 . . . 3 . . . . . Z1 . . . . . 202647 . . . 4 . . . . . 1T . . . . . 038621 . . . 5 . . . . . . . . . . . . . . 038620 . . . 6 . . . . . . . . . . . . . . 081499 . . . 7 . . . . . . . . . . . . . . 206352 . . . 8 . . SR4, SR5 . . 035704 . . . 9 . . . . CB4 . . . . 045061 . . . 10 . . . . . . . . . . . . . . 201697 . . . 11 . . . . . T1 . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly (Continued) . . . 51 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 52 . . . . . . . . . . . . . . 208141 . . Bumper, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 53 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-1. Main Assembly (Continued) . . . 99 . . . . . . . . . . . . . . 228924 . . 100 . . . . R3 . . . . . 189699 . . 101 . . . . . . . . . Figure 12-2 . . 102 . . . . . . . . . . . . . 218086 . . 103 . . . . . . . . . . . . . 189731 . . 104 . . . . . . . . . . . . . 199305 . . 105 . . . . . . . . . . . . . 202637 . . 106 . . . . . . . . . . . . . 223279 . . 107 . . . . . . . . . Figure 12-3 . . 108 . . . . . . . . . . . . . . . . . . ♦ . . 109 . .
4 5 3 6 7 8 2 1 10 9 11 12 13 14 15 17 16 803 203-D Item No. Dia. Mkgs. Part No. Figure 12-2. Control Box Assembly Description Quantity Figure 12-2. Control Box Assembly (Figure 12-1 Item 101) . . . 1 . . . F1, F2 . . *085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . .
Hardware is common and not available unless listed. 3 2 4 5 6 8 1 9 7 35 10 34 11 33 32 31 30 29 27 26 28 25 24 12 (Fig 12−4) 13 23 14 15 22 16 21 20 19 18 Figure 12-3. Panel, Front w/Components Item No. Dia. Mkgs. Part No. Description 17 804 700-B Quantity Figure 12-3. Panel, Front w/Components (Figure 12-1 Item 107) ... 1 .............. ... 2 .............. . . . 3 . . . . . S3 . . . . . .................... . . . . . . . . . . RC6 . . . . . . . 4 . . . . . R1 . . . . . ....
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-3. Panel, Front w/Components (Continued) . . . 6 . . . . . S5 . . . . . 011609 . . . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . . . . . . . . . . . PLG9 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196603 . . . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . .
Hardware is common and 1 not available unless listed. 2 3 4 5 6 20 7 8 9 19 10 11 16 18 15 17 13 12 14 Figure 12-4. Auxiliary Power Panel, High KVA Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-4. Auxiliary Power Panel, High KVA (Figure 12-3 Item 12) . . . 1 . . . . CB1 . . . . 201083 . . . . . . . . . . . . . . . . . . . . 201553 . . . . . . . . . . . . . . . . . . . . 201109 . . . 2 . . . . CB2 . . . . 093996 . . . 3 . . . GFCI-1 . . . 151981 . . . 4 . . . . RC1 . . . .
22 Hardware is common and not available unless listed. 13 17 18 19 20 14 9 12 10 15 16 11 21 8 24 7 23 6 5 25 3 4 1 2 31 30 29 27 26 28 32 34 37 36 33 35 803 204-B Figure 12-5. Generator Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-5. Generator (Figure 12-1 Item 72) . . . 1 . . . . . . . . . . . . . . 132053 . . Screw, 375-16 X 1.50hexhd Pln Gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 183387 . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-5. Generator (Continued) . . . 24 . . . . . . . . . . . . . . 191579 . . . 25 . . . . . . . . . . . . . . 083883 . . . 26 . . . . . . . . . . . . . . 172555 . . . 27 . . . . . . . . . . . . . . 602159 . . . 28 . . . . . . . . . . . . . . 604950 . . . 29 . . . . . . . . . . . . . . 602211 . . . 30 . . . . . . . . . . . . . . 139341 . . . 31 . . . . . . . . . . . . . *190823 . . . 32 . . . . . . . . . . . . . . 208469 . . . 33 . . . . . . . . .
Hardware is common and not available unless listed. 4 3 2 1 5 6 7 8 9 802 279-A Figure 12-6. Main Rectifier Assembly Item No. Dia. Mkgs. Part No. Description Quantity Figure 12-6. Main Rectifier Assembly (Figure 12-1 Item 109) . . . . . . . . . . SR3 . . . . ... 1 .............. ... 2 .............. ... 3 .............. ... 4 .............. . . . 5 . . . . PC3 . . . . ... 6 .............. ... 7 .............. . . . 8 . D3, D5, D7 . . . . 9 . D2, D4, D6 .
Notes OM-228 921 Page 74
Warranty Effective January 1, 2009 (Equipment with a serial number preface of LK or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory.
Owner’s Record Please complete and retain with your personal records. Model Name Purchase Date Serial/Style Number (Date which equipment was delivered to original customer.) Distributor Address City State Contact the Delivering Carrier for: For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA Zip File a claim for loss or damage during shipment.
