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2-1.
VOLT-AMPERE CURVES (Charts 2-1 And
2-2)
The volt-ampere curves show the output voltage and
amperage of the welding generator available at any
point from the minimum to maximum of each coarse am-
perage range. With the use of the volt-ampere curves it
is possible to determine what the weld amperage will be
at a particular arc voltage. The volt-ampere curves show
the minimum and maximum curves of each coarse am-
perage range.
2-2.
DESCRIPTION
This Constant Voltage control panel is designed for use
with the BIG 30 DIESEL, BIG 30A DIESEL, BIG 40 DIE-
SEL, BIG 40G, and BIG 50 DIESEL welding generator
models.
IMPORTANT: If CV-2 was factory installed, proceed di-
rectly to Section 3-2.
3-1.
CV-2 INSTALLATION
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Stop engine, and disconnect negative (–)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
Wear protective gloves and clothing when
working on a hot engine.
Allow unit to cool down, if applicable, before
beginning installation.
Installation to be performed only by qualified
persons.
A. Preparing Unit For Installation
IMPORTANT: On all welding generator models except
BIG 30A DIESEL, it is necessary to move the top cover
back approximately 1 ft. (0.3 m) away from the front
panel to gain access to components.
1.
Remove all necessary top cover securing hard-
ware and components.
2.
Raise both side doors and tie together across the
cover.
SECTION 3 – INSTALLATION OR RELOCATION
The CV-2 expands capabilities of the welding generator
to include constant voltage dc and single–phase ac weld
output selections. A switch is provided for making the ac
selection or for changing the dc polarity. In addition, the
5-socket and 14-socket Amphenol receptacles on this
panel provide a junction point with the unit internal cir-
cuitry for connecting equipment used in Shielded Metal
Arc (SMAW), Gas Metal Arc (GMAW), Flux Cored Arc
(FCAW), and Gas Tungsten Arc (GTAW) Welding proc-
esses.
A 1 ft. (254 mm) adapter cord with 2-prong and 3-socket
plugs to a 14-pin Amphenol plug is required to provide
CV-2 connection capability to wire feed equipment using
an interconnecting cord with 2-socket and 3-prong
twistlock plugs. Other adapter cords and extension
cords with different plug combinations can be obtained
for connecting various welding system devices and con-
trols to the CV-2 receptacles.
3.
Loosen the clamp securing the air cleaner hose
to the engine intake manifold and remove the
hose from the manifold.
4.
For BIG 40 DIESEL, BIG 40G, and BIG 50 DIE-
SEL models: Loosen the clamp securing the
muffler to the exhaust pipe, and remove the muf-
fler from the unit.
5.
Raise and slide cover with side doors approxi-
mately 1 ft. (0.3 m) back over radiator.
CAUTION:
TOOL CONTACT WITH INTERNAL COM-
PONENTS can damage unit.
Cover internal components.
Clean unit, and remove internal covering
material before resuming operation.
6.
On all welding generator models except BIG 30A
DIESEL install key chain onto CV-2 panel as fol-
lows:
a. Drill out the pop rivet securing the key chain to
the lower front panel.
b. Install and secure key with key chain onto CV-2
panel at the prepunched hole location (see Fig-
ure 4-1: hardware not supplied).
7.
Remove and discard lower front panel from unit;
retain securing hardware.
8.
If applicable, disconnect electrode holder and
work clamp cables from weld output terminals.
METAL FILINGS AND/OR
OM-880 Page 3
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Troubleshooting
