SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2011−04 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
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D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —...
1-4. Hydraulic Hazards D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid. or kill. D Reinstall doors, panels, covers, or guards when servicing is D Incorrect installation or operation of this unit finished and before starting unit.
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place.
WELDING WIRE can injure. H.F. RADIATION can cause interference. D Do not press gun trigger until instructed to do D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Do not point gun toward any part of the body, other people, or any metal when threading D Have only qualified persons familiar with welding wire.
1-8. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2011−04 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
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Il reste une TENSION DC NON NÉGLIGEABLE dans les LES RAYONS DE L’ARC peuvent sources de soudage onduleur UNE FOIS le moteur coupé. provoquer des brûlures dans les yeux et sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué...
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, LE BRUIT peut affecter l’ouïe. des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. Le bruit des processus et des équipements peut D Placer les bouteilles debout en les fixant dans un support station- affecter l’ouïe.
D Mettre des lunettes de sécurité et des gants, placer un torchon sur LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur. peuvent provoquer un incendie. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie.
Les PIÈCES MOBILES peuvent causer LES PIÈCES ET LIQUIDES CHAUDS des blessures. peuvent provoquer des brûlures. D S’abstenir de toucher des parties mobiles telles D Ne pas toucher les pièces chaudes à main nue que des ventilateurs, courroies et rotors. ni laisser des liquides chauds entrer en contact avec la peau.
D Remettre en place les portes, panneaux, recouvrements ou PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche. risquent de provoquer des blessures. D Détendre la pression pneumatique des outils et PIÈCES CHAUDES peuvent...
D Demander seulement à des personnes qualifiées familiarisées LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa- QUES peuvent endommager les tion. circuits imprimés. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.
2-8. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-...
4-3. Volt-Ampere Curves The volt-ampere curves show the A. Stick Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the Ranges curves shown. 300 − Max 185 − 525 125 −...
4-6. Generator Power Curve The Standard AC power curve shows the generator power in am- peres available at the 120 and 240 volt receptacles. A. 12 kVA/kW Single-Phase AC Output (No Weld Load) The Three-Phase AC power curve shows the generator output avail- able in amperes at the three-phase 240 volt terminals.
SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the front. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 5-2.
5-3. Mounting Welding Generator Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Weld only on the four mounting brackets or bolt unit down. Supporting The Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets.
5-4. Grounding Generator To Truck Or Trailer Frame GND/PE rot_grnd2 2011−04 − 800 652-D welding generator from the vehicle Equipment Grounding Terminal (On Always ground generator frame to frame. Always connect a ground Front Panel) vehicle frame to prevent electric wire from the generator equipment shock and static electricity hazards.
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. Tools Needed: 1/2 in. Exhaust1 2008−01 Ref. 803 604 / Ref. 202 705 5-7. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a...
5-9. Engine Prestart Checks Check radiator coolant level when fluid is low in recovery tank. Remove air bleed screw when filling radiator. NOTICE − Follow run-in See Section 8-8. Full procedure in engine manu- al. If unburned fuel and oil Full collect in exhaust pipe dur- ing run-in, see Section 10.
5-10. Weld Output Terminals Positive (+) Weld Output Terminal Negative (−) Weld Output Terminal Stick and TIG Welding For Stick and TIG welding Direct Current Elec- trode Positive (DCEP), connect electrode holder cable to Positive (+) terminal on left and work cable to Negative (−) terminal on right.
5-12. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.
5-13. Connecting To Remote 14 Receptacle RC14 Socket* Socket Information 24 volts AC. Protected by supplementary protector CB5. 24 VOLTS AC Contact closure to A completes 24 volt AC contactor control circuit. Output to remote control:+10 volts DC in MIG or Stick mode; 0 to +10 volts DC in TIG mode.
6-2. Description Of Front Panel Controls (See Section 6-1) Engine Starting Controls scheduling maintenance. Voltage/Amperage Adjust Control Use gauge to check fuel level. Engine stops if With Process/Contactor Control switch in any Start/Preheat Switch fuel level is low. Stick or TIG setting, use control to adjust am- Use switch to start engine and operate glow perage within range selected by Amperage To check fuel level when engine is not running...
6-3. Process/Contactor Control Switch 242 336-A Process/Contactor Control Switch Section 6-4). Use Weld Terminals Always On − CC Stick (See Section 6-1 For Location) position for air carbon arc (CAC-A) cutting and gouging. Place switch in Weld Terminals Remotely Weld output terminals are energized When switch is in a Weld Terminals Always Controlled positions to turn weld output on when Process/Contactor Control...
6-4. Remote Voltage/Amperage Control Remote 14 Receptacle RC14 Connect optional remote control to RC14 (see Section 5-13). In Example: Example: Combination Remote Amperage Control (Stick) With Remote On/Off Control Process = Stick (Using Remote On/Off) Range = 125 to 400 A DC Min = 125 A DC Max = 400 A DC Max (400 A DC)
SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. 120 Volt And 240 Volt Receptacles Generator power is not af- fected by weld output. 120 V 20 A AC GFCI Receptacle GFCI1 240 V 30 A AC Twistlock Receptacle RC1 Receptacles supply 60 Hz single- phase power at weld/power speed.
7-2. Connecting To Three-Phase Generator Place Process/Contactor switch in Electrode Hot - Stick position when using three-phase genera- tor (see Section 6-3). Single-Phase Power Connection Single-Phase Generator Power 120/240 V 50 A Receptacle RC5 is connected to the optional three-phase generator and supplies 60 Hz single-phase power at weld/ power speed.
8-2. Routine Maintenance Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference .
8-3. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.
8-4. Inspecting/Cleaning Optional Spark Arrestor Stop engine and let cool. Spark Arrestor Muffler Cleanout Plug Remove plug and remove any dirt covering cleanout hole. 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.
8-6. Adjusting Engine Speed Stop engine and let cool. Engine speed is factory set and should not require adjustment. Af- ter tuning engine, check engine no load speed with a tachometer or fre- quency meter (see table for no load speeds).
8-7. Servicing Fuel And Lubrication Systems Tools Needed: Right Side Ref. 800 159-E / Ref. 802 170 / 804 583-B To drain water from fuel sedimenter: To drain sludge from fuel tank: Stop engine and let cool. After servicing, start engine and Close fuel valve on top of sedimenter.
8-8. Servicing Engine Cooling System Stop engine and let cool. Radiator Cap RAdiator Air Bleed Screw Radiator Drain Cock Drain engine coolant according to procedure in engine manual. Check coolant level according to Section 5-9 before starting this procedure. Engine coolant is a mixture of water and ethylene glycol base anti- freeze.
8-9. Overload Protection Stop engine. 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 out- put stops. 4 kVA/kW generator pow- er 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).
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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.
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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. Have Factory Authorized Service Agent check electric fuel pump, fuel solenoid FS1, control relays CR1 and CR2, engine oil pressure switch S12, engine coolant temperature switch, fuel/hour gauge, and En- gine Shutdown switch S7.
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. Welding Generator Run diesel engines near rated volt- age and current during run-in period to properly seat piston rings and prevent wetstacking.
10-2. Run-In Procedure Using Load Bank Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 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.
10-3. Run-In Procedure Using Resistance Grid Stop engine. Do not touch hot exhaust pipe, engine parts, or load bank/grid. Keep exhaust and pipe away from flammables. 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.
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 Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
11-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE 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.
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11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
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11-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
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11-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
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11-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- Fused Welding Utility al and national, state, and lo- Disconnect Electrical Generator...
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11-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected exten- sion cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts)
SECTION 12 − PARTS LIST Hardware is common and not available unless listed. 109 (Fig.12−5) 101 (Fig.12−2) 107 (Fig.12−3) Figure 12-1. Main Assembly OM-243 907 Page 60...
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Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....+199294 Panel, Gen Lh Stainless ......... .
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Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....189975 Hinge, Door Access 180 Deg........
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Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ....246420 Label, Manufacturing Rating D550K HO Kubota ..... .
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803 203-D Figure 12-2. Control Box Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-2. Control Box Assembly (Figure 12-1 Item 101) ..F1, F2 *085874 Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt ......
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Hardware is common and not available unless listed. 12 (Fig 12−4) 804 700-B Figure 12-3. Panel, Front w/Components Item Dia. Part Mkgs. Description Quantity Figure 12-3. Panel, Front w/Components (Figure 12-1 Item 107) ......Plate, Screened Ident Control (Order By Model And Serial Number) .
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Item Dia. Part Mkgs. Description Quantity Figure 12-3. Panel, Front w/Components (Continued) ... . . 011609 ..Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr ... .
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Hardware is common and not available unless listed. Figure 12-4. Auxiliary Power Panel, High KVA Item Dia. Part Mkgs. Description Quantity Figure 12-4. Auxiliary Power Panel, High KVA (Figure 12-3 Item 12) ... 201083 Supplementary Protector, Man Reset 2p 20a 250vac .
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Hardware is common and not available unless listed. 803 204-B Figure 12-5. Generator Item Dia. Part Mkgs. Description Quantity Figure 12-5. Generator (Figure 12-1 Item 72) ....132053 Screw, 375-16 X 1.50hexhd Pln Gr 5pld .
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Hardware is common and not available unless listed. 802 279-A Figure 12-6. Main Rectifier Assembly Item Dia. Part Mkgs. Description Quantity Figure 12-6. Main Rectifier Assembly (Figure 12-1 Item 109) ...
Warranty Effective January 1, 2011 (Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous manufacturers 90 Days — Parts warranties and is exclusive with no other guarantees or Accessory (Kits) warranties expressed or implied. Canvas Covers Induction Heating Coils and Blankets, Cables, and LIMITED WARRANTY −...
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Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Contact the Delivering Carrier for: File a claim for loss or damage during shipment.