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D550K HO Operator manual - Red-D

1. 1 mri ER 206392 Hose Air Cleaner Intake Kubota V3300 1 ERN O EE RA 207719 Fan Engine Cooling 430mm 6 Blade Pusher 1 E DRE EAM RU 206383 Manifold Exhaust Muffler Kubota V3300 1 M PT NU EET 207722 Gasket Exhaust Manifold Metal d 26825 awstats SEA 218087 Tank Fuel includes fuel cap consisting of 1 ma cc MN 124253 Bushing Tank Fuel 4 ee RE Maa ye teas 189912 Ftg Stl Barbed Elbow W 047in Orifice Zinc Pld 1 mu at AP Beaty 189909 Ftg Stand Pipe Hose 250 X 9 265lg 90 Deg Zinc 1 SB EE 189913 Ftg Stl Barbed Elbow Zinc Pld 1 E EE 190142 Sender Fuel Gauge 9 750 Deep Tank 1 eB esu d d EV ETAA 189910 Ftg Stand Pipe Hose 3125 X 9 260lg 90 Deg Zinc 1 5 2 89 liec eia 189908 Valve Drain Fuel 180 Deg Zinc Pld 1 na 90 us f deberes 181572 Bushing Tank Fuel 1 e 107816 Hose Sae 250 Id X 500 Od Xcoil 41ft CN HE 191446 Extrusion Rubber W Adhesive 1 000 X 1 000 d 4 6 ft 92 FUELPUMP 207721 Pump Fuel Electric 12vdc 1 5a 400 Cc Min 5psi 1 Ec 233482 Kit Fuel Sedimenter
2. 1 bafi at Raph Ee 234714 Bracket Sedimenter 1 sse Ba ssec reete 12063502 BaSsG EE 1 des DV netos a ees e ode 196220 Bracket Holddown Fuel Tank Rear 1 sr BO rione 192362 Bracket Mtg Nyl 1 2 Conduit 0 cee eee 1 nan OT cack bee tan 191897 Bracket Mtg Unit 4 0984 deua 224266 Label Warning Do Not Weld On Base 2 OM 243 907 Page 63 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued 24299 ia ves 246420 Label Manufacturing Rating D550K HO kuboia aaa 1 100 R8 189699 Resistor WW Tap 375 W 10 Ohm W Mtg Bkt 1 ep Ah EE Figure 12 2 Control Box 1 2 TOP riens 218086 Bracket Holddown Fuel Tank 1 ng TOS EEN 189731 Firewall Bottom 1 ng MOF Loses eere 191448 Cover Top Front Upright 1 We NOB SEENEN 201750 Upright Front oroe reun kE Ee NG Banana titi Bes 1 MMOG aces nennen 233953 Label Warning General Precautionary CSA 1 107 Figure 12 3 Panel Front w Components 1 nG NOB NA a ne Transformer C rrent Ae a NENNEN PAD Eed ENNEN TAGA NADA NAG 1 109 SR3 Figure
3. 3 EE DEER 188135 Enclosure Rectifier 2 T ET 134201 Stand off Support ees 3 5 PC3 215755 Circuit Card Assembly Protection 1 E 188136 Insulator Heat Sink 8 RAI TE 188493 Heat Sink Rectifier Al 2 8 D3 D5 D7 245097 Diode Rect 300 A 500v Do 9 Straight Modified 3 9 D2 D4 D6 245096 Diode Rect 300 A 500v Do 9 Reversed Modified 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 Base Group OM 243 907 Page 71 Notes DECIMAL EQUIVALENTS 015625 o3 Oe Se 9 8 Se 066 5 Se Se Se e 9 660 32 Bez Ze PT 99 909 Se oo Se Be 0 33 Se 09 CS 6 Bk Se Se Se e 9 Og 3 o OM 243 907 Page 72 Warranty Effective January 1 2011 Equipment with a serial number preface of MB or newer This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY
4. 1 WERE S ENEE EE 602242 Washer Flat 375idx0 8750dx 083t Stl Pld 2 mc Um 602211 Washer Lock 318idx0 5860dx 078t Stl Pld Split 312 2 GD c 604534 Screw 312 18x1 25 Hex Hd pln Gr5 Pld 2 EP 190259 Harness Brush Consisting Of disse aries PLG1 168071 Connector Kit Rect Univ 084 9p S 3 Row Plug Cable Lkg 1 SE eebe a GG eus 187651 Seal Wire Univ 9p S 3 Row 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of label kit 210 738 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 243 907 Page 70 x Hardware is common and not available unless listed 802 279 A Figure 12 6 Main Rectifier Assembly Item Dia Part No Mkgs No Description Quantity Figure 12 6 Main Rectifier Assembly Figure 12 1 Item 109 oM ees SR3 239784 Rectifier Environmental High Power Consisting Of 1 ONG WEE 188137 Connection Board Rectifier Ac 1 MODICO ME 188517 Bus Bar Connection Board
5. 1 Teteres da 214927 Boot Circuit Breaker 1 Pole 1 jc 197508 Plug Protective 1 E rero ets 077440 Bushing Conduit in 1 eege 601836 Nut 250 20 50hex 19h Brs 3 10 bns 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 17 sper REG 209056 Cover Receptacle W Gasket 3 eu VC EEN 127011 Rivet Al 187 Dia X 251 375 Grip Blind Domed Hd 12 ae ho eens een eee ne 197399 Label Warning 3Ph Generator Power 1 e iu do ta ichs re 206795 Boot Circuit Breaker Clear Hex Nut 1 When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of label kit 210 738 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 243 907 Page 68 EF Hardware is common and not available unless listed 803 204 B Figure 12 5 Generator Item Dia Part No Mkgs No Description Quantity Figure 12 5 Generator Figure 12 1 Item 72 zc WEEN 132053 Screw 375 16 X 1 50hexhd Pin Gr 5pld 6 Que rx Kabag pan 183387 Washer Conical Spring 406 I
6. 2 8 Principales normes de s curit 2 9 Informations relatives aux CEM SECTION 3 DEFINITIONS 3 1 Symbols And Definitions SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications 4 2 Dimensions Weights And Operating Angles 4 3 Volt Ampere Curves 4 4 Fuel Consumption 4 5 Duty Cycle And Overheating 4 6 Generator Power Cure SECTION 5 INSTALLATION 5 1 Serial Number And Rating Label Locatio 5 2 Installing Welding Generator 5 3 Mounting Welding Generator Napaan ee NAN EEN 5 4 Grounding Generator To Truck Or Trailer Frame 5 5 Using Lifting Eye 5 6 Installing Exhaust Pipe 5 7 Activating The Dry Charge Battery If Applicable 5 8 Connecting The Battery 5 9 Engine Prestart Checks 5 10 Weld Output Terminals 5 11 Connecting Weld Output Cables 5 12 Selecting Weld Cable Sizes 5 13 Connecting To Remote 14 Receptacle RC14 1 1 eh SECTION 6 OPERATING WELDING GENERATOR 6 1 Front Panel Controls See Section 6 2 6 2 Description Of Front Panel Controls See Section 6 1
7. 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 mm for metric use For distances longer than those shown in this guide call a factory applications rep at 920 735 4505 Miller or 1 800 332 3281 Hobart Ref S 0007 J 2011 07 OM 243 907 Page 28 5 13 Connecting To Remote 14 Receptacle RC14 804 582 A 7 ever 1 Socket Socket Information A 24 volts AC Protected by supplementary protector CB5 24 VOLTS AC OUTPUT B Contact closure to A completes CONTACTOR 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 REMOTE D Remote control circuit common OUTPUT CONTROL 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 supplementa 115 VOLTS AC ry protector CB13 OUTPUT CONTACTOR Contact closure to completes J 115 volt AC contactor control circuit GND K Chassis common NEUTRAL G Circuit common for 24 and 115 volt AC circuit The remaining sockets are not used OM 243 907 Page 29 SECTION 6 OPERATING WELDING GENERATOR
8. 240V 3 Phase Tools Needed ED E CES Place Process Contactor switch in Electrode Hot Stick position when using three phase genera tor see Section 6 3 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 2 Supplementary Protector CB7 CB7 protects single phase recep tacle RC5 and the load wires from overload If CB7 opens all three phase generator output stops and the receptacle does not work Three Phase Generator Power A Stop engine A Power and weld outputs are live at the same time Discon nect or insulate unused cables 7 Have qualified person install ac cording to circuit diagram and Generator Power Guidelines in Owner s Manual Remove generator power panel mounting screws Tilt panel forward 3 Lead 93 4 Lead92 5 Lead91 6 Lead 42 Circuit Grounding Lead 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 discon nected from neutral to meet applica ble 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 ter minals on C
9. 6 3 Process Contactor Control Switch 6 4 Remote Voltage Amperage Control 6 5 Fuel Hour Gauge Descriptions SECTION 7 OPERATING AUXILIARY EQUIPMENT 0 00 cece RII nnn 7 1 120 Volt And 240 Volt Receptacles 7 2 Connecting To Three Phase Generator o NN OO BR OC A GO GO Co Ca CG OQ ON N N N N N N N N N N N N N N ch A ch ch mb ch eh A ch ck ch ch ch a O O GO ON NN DO O ES Co AN zz 2 O O DJ d d OO OO BB ON TABLE OF CONTENTS SECTION 8 MAINTENANCE 8 TROUBLESHOOTING 37 8 1 Maintenance Label aaa vanes bbe a elias NEE SE EE er Rex EFE E ne 37 8 2 Routine Maintenance terat P EY SU e VERRE RS LITT en mens 38 8 3 Servicing AI UA EIER E P EXER A Aa EE PO TE RE Ze EFTREE TURA 39 8 4 Inspecting Cleaning Optional Spark Arrestor 40 8 5 Checking Generator Brushes 40 8 6 Adjusting Engine Speed 41 8 7 Servicing Fuel And Lubrication Systems 42 8 8 Servicing Engine Cooling System 43 8 9 Overload Protection 44 8 10 Troubleshooting Tables EELER eee eee eee DAG Pee ird p ete 45 SECTION 9 ELECTRICAL DIAGRAM en n nnn nenne 48 SECTION 10 RUN IN PROCEDURE nunsuzunununusususuzuzunzuzuz
10. OM 243 907 Page 37 8 2 Routine Maintenance e A 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 A Me Recycle engine fluids V Check Change Clean Replace Reference RE Qr bris To be done by Factory Authorized Service Agent Every LE de ps Section 5 6 l 1 Coolant Level Fuel Level Oil Level Q Oil Fuel Spills Q Sedimenter Bowl Every 50 p SEN Hours i 2 Q Weld Terminals Every Section 8 3 100 16 in Engine Hours fuh P Manual Air Cleaner Hoses Belt Tension Q Battery Terminals Every NOTICE Change engine x E Section 8 7 200 oil and filter after initial 50 to Ki 5 Hours 75 hours of use E Oil Oil Filter Radiator Hoses Unreadable Labels Every Engine 500 Manual Hours G Section 8 4 8 8 wk Weld Cables C Opt Spark Arrestor Every Section 8 7 800 Engine Hours Manual Every Engine 1000 Manual Hours Section 8 5 8 7 X Brushes Q Inside Unit Q Drain Sludge C Slip Rings Every 1500 Hours Every Section 8 3 Year Every Section 8 8 2 Engine Years Manual Coolant And Hoses OM 243 907 Page 38 8 3 Servicing Air Cleaner zar NU ENGINE SHUTDOWN
11. Utility Electrical Service Transfer Switch Essential Loads Fused Disconnect Switch If Required Welding Generator Output A Have only qualified persons perform these connections according to all applicable codes and safety practices A Properly install ground and operate this equipment ac cording to its Owner s Manu al and national state and lo cal codes Customer supplied equipment is required if generator will sup ply standby power during emergencies or power out ages 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 re stored Install correct switch customer supplied 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 volt age an
12. sion cord Current Maximum Allowable Cord Length in ft m for Conductor Size AWG Amperes Load Watts 4 6 8 10 12 14 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 296 voltage drop OM 243 907 Page 59 SECTION 12 PARTS LIST Hardware is common and not available unless listed 15 14 Figure 12 1 Main Assembly OM 243 907 Page 60 804 572 D OM 243 907 Page 61 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly TU rds RIS S 4 199294 Panel Gen Lh Stainless 1 PARAAN 199301 Panel Engine Side Stainless Stl 1 D EN FA ME 202647 Reactor AC Environmental 1 do accus TT ss 038621 Block Term 30 Amp 4 Pole Frict Term Str Both Side 1 DIO dt A TAS 038620 Link Jumper Term Blk 30 Amp 1 SO iiec
13. L installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne a l cart et plus particuli rementles enfants UN CHOC LECTRIQUE peut tuer Un simple contact avec des pieces lectriques peut provoquer une lectrocution ou des blessures gra ves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galementsous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne compor tant pas de trous e S isoler de la piece et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne passe servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique courant lectrique UNIQUE MENT si le proc d de soudage le demande e Sil utilisation d une source lectrique coura
14. 1 Resistance Grid Use grid sized for generator rated output Turn Off grid 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum 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 connec tors polarity is not important 4 Voltmeter P 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 ad just 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 weld ing generator for two hours mini mum 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 A Stop engine and let cool 6 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0684 OM 243 907 Page 52 SECTION 11 GENERATOR POWER GUIDELINES x The views in this section are intended to be representative of all engine driven welding generators You
15. Check and secure connections to Remote 14 receptacle RC14 see Section 5 13 Repair or replace remote control device Wire feeder does not work with welding generator Reset supplementary protector CB5 or CB6 see Section 8 9 Check and secure connections to Remote 14 receptacle RC14 see Section 5 13 OM 243 907 Page 45 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 AmperageAdjust 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 Standard Generator Power Trouble Remedy No generator power output at AC recept acles weld output okay Reset receptacle supplementary protectors No generator power output at AC recept acles no weld output Disconnect equipment from generator power AC receptacles during start up Reset supplementary protector CB12 see Section 8 9 Have Factory Authorized Service Agent check field current regulator board PC1 Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 and rotor Have Factory Authorized Service Agent check slip rings install n
16. Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 7 Proposition californienne 65 Avertissements A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants A Les batteries les bornes et autres accessoires contiennent du plomb et des compos s a base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation A Ce produit contient des produits chimiques notamment du plomb dont l tat de Californie reconna t q
17. e Charge lead acid batteries only Do not use battery charger to supply power to an extra low voltage electrical system or to charge dry cell batteries Do not charge a frozen battery Do not use damaged charging cables Do not charge a battery that has loose terminals or one showing damage such as a cracked case or cover e Before charging battery select correct charger voltage to match battery voltage e Set battery charging controls to the Off position before connect ing to battery Do not allow battery charging clips to touch each other Keep charging cables away from vehicle hood door or moving parts i FUEL can cause fire or explosion d e Stop engine and let it cool off before checking or adding fuel e 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 Le MOVING PARTS can injure e Keep away from moving parts such as fans ty belts and rotors e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary e To prevent accidental starting during servicing disconnect nega
18. position Dimensions vary with loca tion of mounting brackets F Weight B S No fuel 1808 Ib 820 kg 802 161 A Lifting Eye Weight Rating EE 2380 Ib 1079 kg Maximum Meets IEC Srtandard 60 974 1 OM 243 907 Page 17 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 1 ng Ranges other settings fall between the 300 Max curves shown 80 ci 185 525 H 125 400 2 Be 125 H 60 i O gt amp 40 20 0 i H y 0 100 200 300 400 500 600 700 800 2900 1000 DC AMPERES B MIG Mode 100 80 o Em O gt QO Q 0 100 200 300 400 500 600 700 800 900 1000 DC AMPERES C TIG Mode 100 Ranges 60 450 80 o H 60 gt B 40 20 amp 0 Li Lab yl EE TAA TE TERE E CEE GE GE D PEE E ge puce EE 0 100 200 300 400 500 600 700 DC AMPERES 208 135 203 415 208 136 OM 243 907 Page 18 4 4 Fuel Consumption The curve shows typical fuel use under weld or power loads g I D z D a J D 11 35 3 00 10 40 2 75 9 46 2 50 8 51 2 25 T 7 57 2 00 f 6 62 1 75 5 67 1 50 f 4 73 1 25 3 78 1 00 2 84 0 75 1 98 0 50 F 0 95 0 25 0 00 0 00 0 100 200 300 400 500 600 700 DC WELD AMPERES AT 10096 DUTY CYCLE 208 137 4 5 Duty Cycle And Overheating uu 1 l ii Tema Sen utes that unit can weld at rated load
19. 8 ool estie gite 181169 Spacer Output Stud 2 owe NEEN 186621 Boot Generic Output Stud 2 Besse ta stre 059771 s Handle Switehi i2 ecen ideam Cine oe RENT PROC TER NE CR 1 HERO Loss Area 010647 Pin Spring cs 156 x 1 250 1 23 POSITIVE 241432 Terminal Pwr Output Red 1 LOCA adds edu 021385 Boot Toggle Switch Lever 2 Da DD saw AW Oa AS 190323 Boot Circuit Breaker Clear Hex Nut 3 nan 20 cus 170391 Conn Circ Ms Protective Cap Size 20 Nylon 1 27 FUEL HM 233095 Gauge Fuel Elec Hour Meter 1 E prm AM 118060 Meter Amp Dc 60 0 60 2 250 Dia High Profile Stainl 1 29 TEMP 193229 Gauge Coolant Temp 0 300 Deg F Electric Switch 1 sued stes aste curet 6164873 Meter Weld Amps 1 aded BEE EE 6164874 Meter Weld Volts 1 TON LE adie anh 097922 Knob Pointer 875 Dia X 250 Id W Set Screwsplstc 1 Ser EE 189161 Handle Switch Range 1 NU ER 010647 Pin Spring Cs 156 X 1 250 1 EE 097924 Knob Pointe
20. Grommet Plastic Neck Filler Fuel 1 wu E 190198 Cap Tank Screw on 3 500 In W Vent W Lanyard included w tank 1 23a eae A EAS 192041 Label Use Diesel Fuel Only 1 P d 222513 Label Warning Falling Equipment Can Cause Serious 1 EE E 224265 Label Warning Hot Exhaust Parts Do Not Touch 1 26 wi vat adiu 105734 Pipe Muffler Extension Elbow 1 750 Od 1 sa OT ae ra oa xA 202629 Cover Radiator Access Stainless 1 28 RE ts 202633 Support Cover E Coat anneau aa 1 Mu WA 010875 Clamp Muffler 2 000 Dia U Pld 1 E NEE 225120 Label Warning Moving Parts Can Cause Injury 6 AG NEE 210725 Guard Fan Left AA KA eee NANA 1 EE PE 206517 Radiator W Shroud amp 7 Cap 4row Core Assy Rda consisting of 1 AA PA Tee 206518 Radiator Big Blue Air Pak BEE 605982 Cap Radiator Pressure 7 Lb 1 see Ber ARA dra 206384 Shroud Radiator Kubota 1 24 08 ta eru 207192 Panel Engine Extension L h Stainless 1 EL Included in item 35 D dicite ets 201749 Upright Rear Radiator 1
21. Ne pas charger une batterie gel e e Ne pas utiliser de cables de charge endommag s e Ne pas charger une batterie dont les bornes sont desserr es ou pr sentant une d t rioration comme par exemple un bo tier ou un couvercle fissur e Avant de charger une batterie s lectionner la tension de charge correspondant la tension de la batterie OM 243 907 Page 10 R gler les commandes de charge de batterie sur la position d arr t avant de brancher la batterie Veiller ce que les pinces de charge ne se touchent pas Ranger les c bles de charge distance du capot des portes et des pi ces mobiles du v hicule i e LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d tincel les ou d une flamme nue Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur Jeter les chiffons dans un r cipient ignifuge Toujours garder le pistolet en contact avec le r servoir lors du remplissage m Les PIECES MOBILES peuvent causer des blessures v e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors Maintenir ferm s et verrouill s les portes recouvrements et dispositif
22. TIG 60 450 STICK 85 250 TIG 30 220 trate EES N Set V A Set Remote PAX i i t Ran t Control Adjust Switch Process Set Range Set Contro In Example Process TIG Using Remote On Off Range 40 to 330 A DC Percentage Of Range 5096 Min 40 A DC Max About 185 A DC 50 of 40 to 300 Max 185 DC P Min 40 A DC Adjust Optional Remote Control 0774 Ref 192 895 A 804 582 A 242 336 A OM 243 907 Page 33 6 5 Fuel Hour Gauge Descriptions FUEL HOUR GAUGE DESCRIPTIONS ENGINE HOURS Gauge will display engine hours while engine is running To display engine hours while the engine is off place Engine Control ZS switch in position 1 then default back to position 2 5 OIL CHANGE INTERVAL Gauge will display hours remaining before oil change is due with Engine Control switch held in position 1 with engine off OIL CHANGE DUE Gauge will display blinking wrench when oil change is due 0 to 99 hours To Reset Toggle Engine Control 4 o switch between position 1 and 2 three times within 5 seconds engine off LOW FUEL PREWARNING Fault indicator flashes when fuel level reaches 2 bars Flashing rate increases as fuel level drops LOW FUEL Fuel level low when fuel icon and last bar in fuel gauge blink To Reset Refuel NO FUEL Engine shuts down before fuel runs out Display shows noFuel and fuel
23. Motor Start G H J K L M N P Code KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage A r OND Step 1 Find code and use table to 4 AC MOTOR find kVA HP If code is not listed 1 SR VOLTS 230 AMPS 2547 2 multiply running amperage by six to find starting amperage ODE UM Ke 60 Step 2 Find Motor HP and Volts HP 1 4 PHASE 1 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 K Example Calculate starting amper age required for a 230 V 1 4 HP mo tor 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 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5Second 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 243 907 Page 57 11 10 Typical Connections To Supply Standby Power EZ
24. Replace Damaged Brushes A 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 JOS New Length 1 1 4 in 32 mm OM 243 907 Page 40 8 6 Adjusting Engine Speed A Stop engine and let cool Engine speed is factory set and J 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 If necessary adjust speed as follows ENGINE SHUTDOWN Push down to shut off engine 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 Do not set engine speed higher than specified 3 Engine Shutdown Lever Use lever to stop engine if Engine Shutdown switch does not work A Stop engine Close door CS 1850 rpm Max 61 6 Hz Tools Needed Qe 804 583 A Ref 242 336 A OM 243 907 Page 41 8 7 Servicing Fuel And Lubrication Systems A A t3 ah a Tools N
25. e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 243 907 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 e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e 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 e 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 t
26. If unburned fuel and oil collect in exhaust pipe dur ing run in see Section 10 Remove air bleed screw when filling radiator See Section 8 8 engine maintenance label for fuel specifica tions Leave filler neck empty to allow room for expansion Engine stops if fuel level is low Cil After fueling check oil with unit on level sur face If oil is not up to full mark on dipstick add oil see maintenance label NOTICE Engine may use oil and wets tacking may occur during run in Check oil several times daily during run in Coolant Check coolant level in radiator before start ing unit the first time Add coolant if below bottom of filler neck see Section 8 8 for ra diator filling instructions Check coolant level in recovery tank daily If coolant is below Cold Full level add cool ant until level in tank is between Cold Full and Hot Full levels If recovery tank coolant level was low check coolant level in radiator see Section 8 8 Check radiator coolant level when fluid is low in recovery tank Capacity w Overflow Tank 10 qt 9 5 L Coolant Recovery Tank 804 583 A Engine coolant is a mixture of water and ethylene glycol base antifreeze A solution of 5096 antifreeze and 5096 water must be used in this engine Do not use 10096 anti freeze or severe damage will occur Keep radiator and air intake clean NOTICE Incorrect engine temperature can damage engine Do n
27. 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 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 243 907 Page 55 11 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 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 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 1HP 20 in 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 HP 4500 1400 1HP 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 243 907 Page 56 11 8 Power Required To Start Motor Single Phase Induction Motor Starting Requirements
28. NG IN without overheating NOTICE Exceeding duty cycle can damage unit and void warranty Continuous Welding 1000 800 600 500 400 500 250 200 WELD AMPERES 150 100 10 15 20 25 30 40 50 60 80 100 DUTY CYCLE 202 356 OM 243 907 Page 19 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 150 300 240 volt terminals 125 250 100 200 N Qi 150 AC VOLTS Qi o 100 n2 O1 50 o 0 o 5 10 15 20 25 30 AC AMPERES IN 240V MODE 10 20 30 40 50 60 AC AMPERES IN 120V MODE o B 20 kVA kW Three Phase AC Output No Weld Load 280 260 240 220 AC VOLTS 200 180 AC AMPERES 193 018 197 473 OM 243 907 Page 20 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 Installing Welding Generator A Do not move or operate unit where it co
29. 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 THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below manufacturer will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Manufacturer must be notified in writing within thirty 30 days of such defect or failure at which time manufacturer will provide instructions on the warranty claim procedures to be followed Manufacturer shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the delivery date of the equipment to the original end user purchaser and not to exceed one year after the equipment is shipped to the distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers only to include SCRs diodes and discrete rectifier modules 2 3 Years Parts and Labor Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer Inverter Power Sources Unless Otherwise Stated Plasma Arc Cutting Power Sources Process Controllers Semi Automatic and Au
30. sur la PEAU e Ne pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau E 4 LA CHALEUR DU MOTEUR peut pro 4 voquer un incendie e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement Le LIQUIDE HYDRAULIQUE risque de provoquer des blessures ou m me la mort e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations hydrauliques e Avant Q utiliser l appareil contr ler les composants du circuit hydraulique les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure e Pourintervenir sur un circuit hydraulique porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser un morceau de papier ou de carton jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement e Le LIQUIDE HYDRAULIQUE est INFLAMMABLE Ne pas intervenir sur des composants hydrauliques proximit d tincelles ou de flam
31. use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes e Do not work on compressed air system with unit running unless you are a qualified person and following the manufacturer s in structions e Do not modify or alter compressor or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the compressed air system e Use only components and accessories approved by the manufac turer e Keep away from potential pinch points or crush points created by equipment connected to the compressed air system e Do not work under or around any equipment that is supported only by air pressure Properly support equipment by mechanical means 4 HOT METAL from air arc cutting and MOVING PARTS can injure h f gouging can cause fire or explosion e Keep away from moving parts such as fans e Do not cut or gouge near flammables Ng belts and rotors e Watch for fire keep extinguisher nearby e Keep all doors panels covers and guards closed and se
32. 081499 Bracket Mtg Terminal Strip 1 vau ol Laits a Nimes 206352 Brace Front To Center Upright 2 8 SR4 SR5 035704 Rectifier Integ Bridge 40 Amp 800v 2 9 CB4 045061 Circuit Breaker Auto Reset 24vdc 7 Amp 1 TO goa 88 cane eas 201697 Pan Reactor amp rectifier 1 TT Lu less 205636 Transformer W Brkt Environmental 1 AAP 173352 Extrusion Rubber Clamp Bulb 2 75 ft E WEE 189708 Firewall Top 1 E Bp e cest 206697 Hose Elbow Air Cleaner 1 UE 206393 Pipe Air Cleaner Intake Kubota V3300 1 TO GE 189763 Bracket Mtg Air Cleaner 1 df EE 189764 Air Cleaner Intake consisting of 1 ERE 192938 Filter Air Element Primary d Rog ve ae TEE 6192939 Filter Air Element Safety 1 Ee Ae 189464 Seal Weather Lift Eye 2 cent nets 1 T9 AA NAAN 206351 Upright Center Assy 1 Sue vow ex etu hg ds 206541 Cover Top Stainless Steel 1 EE 189052
33. 164617 Clip Wiring Straight 2 Dau eos RC10 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 1 wu 7 CB5 139266 Supplementary Protector Man Reset 1p 15a 250vac 1 Re Aca lng CB13 139266 Supplementary Protector Man Reset 1p 15a 250vac 1 Dx EEN 202209 Spacer Nylon eee kee PAGG BLG AD ut eee Edu 2 9 PC6 192995 Circuit Card Assy Connector Receptacle 1 ed aoe ets ST una 207720 Switch Ignition 3 Position Mom off mom W Handle 1 us a SE ST Less 199691 Switch Tgl Spdt 6a 125vac On none mc Spd Term included in EE engine harness see Figure 12 2 1 cx dtr e Figure 12 4 Auxiliary Power Panel High KVA 1 DS A 196073 Label Do Not Switch While Welding 1 ULM 220491 Switch Polarity AC 1 PUT 195825 Switch Polarity 1 xi dotate edes 201125 Panel Mtg Terminal Power Output 1 16 PC4 PC5 189744 Circuit Card Assy Filter Hf 2 17 NEGATIVE 241433 Terminal Pwr Output Black 1 er NB iuter lv 134201 Stand off Support Pc Card 312 375w Post amp lock 43
34. 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure 6 Ne pas travailler proximit d une source de soudage ni s asseoir ou se pencher dessus 7 Ne pas souder tout en portant la source de soudage ou le d vidoir En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 243 907 Page 15 SECTION 3 DEFINITIONS Read Operator s Circuit Protector Do Not Switch 3 1 Symbols And Definitions Fast Run Weld Gi Stop Engine Mali gt Slow Idle 2 Start Engine Starting Aid Battery Engine Fe Sp Engine Oil Check Injectors Check Valve Fuel Protective Earth Pump Clearance e Ground NN Positive Negative L i MS Welding Arc A Amperes V Volts Panel Local La Remote Air Temperature Or Q lt Engine Engine Output Ni Airing v y Temperature UH Stick SMAW Constant Current G MIG GMAW E oe Welding Si CO KIA Welding DE TIG GTAW Time h Hours Seconds 1 Ni Single Phase 2e en Three Phase Manual o o While Welding Engine Driven Electrode A Three Phase H Connection mm Wo
35. 6 1 Front Panel Controls See Section 6 2 5 8 ZA DO NOT SWITCH UNDER LOAD N Place switch in WELD TERMINALS ALWAYS ON positions for weld output to be on whenever the engine is running WELD TERMINALS ALWAYS ON PROCESS CONTACTOR CONTROL P X 12550K HO CC CV DC Diesel Welder N Q Q VOLTAGE AMPERAGE ADJUST CONTROL Adjusts STICK TIG Amperage and MIG Voltage ENGINE SHUTDOWN Push down to shut off engine Panel Place switch in WELD TERMINALS REMOTELY CONTROLLED positions to tum weld output on and off with a device connected to the Remote 14 Pin Receptacle Use CC STICK position for air carbon arc CAC A cutting and gouging o NEUTRAL BONDED TO FRAME V NEUTRE RAGGORD AU BATI gt For remote VOLTAGE AMPERAGE g o control place switch in Remoie I S position and connect remote control o 5 to Remote 14 Pin Receptacle 5 WELD TERMINALS REMOTELY CONTROLLED Starting Ins ructions Turn the Start Pre eat switch to the Preheat position Turn Coun Clockwise Above 3 G 41 F pre eat for 5 seconds Below 5 C 41 F pret Nat tor 15 seconds This wil heat the glow Mu and the engine combustion chambers 2 To crank and start the er ine turn Start Preheat switch clockwise to the prt position Release the switch when eX ine staris 3 If the engine does not start thin 15 seconds release the switch and ste steps 1 and 2 M
36. Guns and Subarc SAW Guns Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Exception brushes and relays are covered on all engine driven products 2 Items furnished by manufacturer but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT zz zz zt OF In the event of a warranty claim covered by this warranty the exclusive remedies shall be at manufacturer s option 1 repair or 2 replacement or where authorized in writing by manufacturer in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the pur
37. Push down to shut off engine y Optional OX ANANAS RSS ANNA Keep nozzle 2 in 51 mm from element OX en Xd NANO ROX A ON X A d di N x YN d 8 A KK o 7 KK ANA NA KK p S Blow K K KAKA XXX AVAA YAYA GN M A X XX di M XX KAA KN di KR 8 d WV x M OX Inspect A 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 E The air cleaner primary element can be cleaned but the dirt holding capac ity of the filter is reduced with each cleaning The chance of dirt reaching the clean side of the filler while clean ing 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 ment If you decide to clean the primary ele ment we strongly recommend instal ling an optional safety element to pro vide additional engine protection Never clean a safety element Re place the safety element after servic ing the primary element three times Clean or replace primary element if dirty see note above before cleaning Re place primary element if damaged Re place primary element yearly or after six cleanings 1 Housing 2 Safety Element Optional 3 Primar
38. RC3 WBS 5138 gt gt 94 a a ABA 206 7 gt 106 205 gt 108 208 9 gt 108 210 UOS S LO ZZ PLG6 RC6 125 Ss a 12615 5126 56 BEE 54 PLG10 RC10 ge E 136 S ro 3 5426 gt 4 gt 778 US 7 116 8 ER 9 ER o RC14 K J gt c gt E gt D gt c gt B gt AS CB5 121 AN N 42 FILTER BOARD 119 87 e 116 AUX STATOR a2 STCK TIG S6 e o TH STANDARD RECEPTACLE PACKAGE o Om Oz doo oF 67 AA 3 10 RC2 PLG14 PC6 AUX STATOR 8 AUX STATOR ron 120V wH E JIN GND 42 137 106 Lee 105 lt lt 8 129 127 PANEL S5 128 REMOTE S 117 T 118 RC2 PLG14 6 gt EE SF i RMT 5 119 HOT OUTPUT 4 127 CONTACTOR K 42 5 gt be deg PLG13 12 gt 2 2 3 m4 255 141 i Ss s 50 OM 243 907 Page 48 n H S6 REMOTE ELECTRODE HOT SWITCH NUMBERS LEAD NUMBERS TIG MIG STICK TIG 1 2 119 120 x STICK x MIG 2 3 120 121 x x 5 6 122 123 x 6 7 123 124 9 10 48 68 X X x 11 12 84 98 X CONTACT C
39. 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 5096 of 125 to 400 A E The numbers around the control are for reference only and do not represent an ac tual percentage value 9 Voltage Amperage Adjust Control Switch And Remote 14 Receptacle Use switch to select front panel or remote volt age amperage control For remote control place switch in Remote position and connect remote control to Remote 14 receptacle RC14 see Sections 5 13 and 6 4 10 Polarity AC Selector Switch Optional NOTICE Do not switch under load Use switch to change weld output Select ei ther DC Electrode Positive DCEP or DC Electrode Negative DCEN Weld Meters 11 DC Voltmeter Optional Voltmeter displays voltage at the weld output terminals but not necessarily the welding arc due to resistance of cable and connections 12 DC Ammeter Optional Ammeter displays amperage output of the unit OM 243 907 Page 31 6 3 Process Contactor Control Switch Place switch in WELD TERMINALS ALWAYS ON positions Place switch in WELD TERMINALS REMOTELY CONTROLLED for weld output to be on whenever the engine is running positions to turn weld output on and off with a device connected to the Remote 14 Pin Receptacle PROCESS CONTACTOR CONTROL WELD TERMINALS WELD TERMINALS ALWAYS ON REMOTELY CONTROLLED Use CC ST
40. achev assurez vous qu il ne reste aucune tra ce d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit OM 243 907 Page 9 LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sonore est trop lev Les CHAMPS LECTROMAGN TIQUES CEM peuvent affecter les implants m dicaux e Les porteurs de stimulateurs cardiaques et autres implants m dicaux doivent rester distance e Les porteurs d implants m dicaux doivent consulter leur m decin et le fabricant du dispositif avant de s approcher de la zone ou se d roule du soudage l arc du soudage par points du gougeage de la d coupe plasma ou une op ration de chauffage par induction Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma gee elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages ph
41. 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 name plate rating label or the specifi cations 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 weld ing generator for two hours mini mum and up to four hours under load Place AV control in minimum position then turn off load bank to remove load Run engine several minutes at no load A Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present S 0683 OM 243 907 Page 51 10 3 Run In Procedure Using Resistance Grid pA A t NU C 1 Stop engine A Do not touch hot exhaust pipe engine parts or load bank grid A 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
42. body seek medical help im mediately e To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns BREATHING COMPRESSED AIR can in jure or kill READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each TRAPPED AIR PRESSURE AND WHIPPING section HOSES can injure e Use only genuine replacement parts from the manufacturer e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes e Do not use compressed air for breathing e Use only for cutting gouging and tools 4 e Release air pressure from tools and system be fore servicing adding or changing attach ments or opening compressor oil drain or oil fill cap 1 6 Additional Symbols For Installation Operation And Maintenance CA ALI FIRE OR EKPLOSION hazard OVERHEATING can damage motors e Turn off or unplug equipment before starting or stopping engine e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not let low voltage and frequency caused by e Do not overload building wiring be sure power supply system is low engine speed damage electric motors properly sized rated and protected to handle th
43. contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le cable de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s pos sible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur UNE FOIS le moteur coup e Couper l alimentation du poste et d charger les condensateurs d entr e comme indiqu dans la Section Maintenance avant de toucher des composants LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher mains nues les parties chau des e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures DES PIECES DE METAL ou DES wo SALETES peuvent provoquer des blessures d
44. correctement cet quipement conform ment son Manuel d Utilisation et aux r glementations nationales gouvernementales et locales e Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e Eneffectuant les raccordements d entr e fixer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e Les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chau des e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement sil est endommag un c ble d nud peut provoquer une lectro cution e Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour e Ne pas toucher l lectrode quand on est en
45. distributor OM 243 907 Page 67 x Hardware is common and not available unless listed Figure 12 4 Auxiliary Power Panel High KVA Item Dia Par No Mkgs No Description Quantity Figure 12 4 Auxiliary Power Panel High KVA Figure 12 3 Item 12 1 CB1 201083 Supplementary Protector Man Reset 2p 20a 250vac 1 EEN 201553 Clip Retaining Circuit Breaker 1 Vago TERRAE Rule ie 201109 Harness Receptacle Auxillary Power consisting of 1 2 CB2 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 1 3 GFCI 1 246865 Rept Str Dx Grd 2p3w 20a 125v 5 20r Gfi 1 4q RC1 147632 Rept Tw Lk Grd 2p3w 30a 250v L6 30r 1 Na 010146 Clamp Nyl 625 Clamp Dia X 500 Wide 203 Mtg Hole 2 5 RC5 182954 Rcpt Str 3p4w 50a 125 250v Flush Mtg 14 50 1 625k Sakae Pas 025248 Stand off Insul 250 20 X 1 250 Lg X 487 Thd 1 KEEN 604102 Conn Clamp Cable 1 000 1 Bi ANA Baan 197527 Guard Circuit Breaker 0 n 1 GETT 197363 Terminal Ring Tng Screw Clamp 14ga 6ga 3 10 CB7 214926 Supplementary Protector Man Reset 3p 50a250vac 1 uc 215363 Panel Aux Power W High Kva
46. engine is not running place Engine Control switch in Preheat posi tion then default back to neutral position See Section 6 5 for complete fuel hour gauge information 4 Battery Ammeter Use gauge to check amperage output to the battery The gauge reads near O zero when the engine is running If gauge is at a negative number the battery is discharging NOTICE Stop engine and do not run engine until problem is fixed 5 Engine Temperature Gauge Normal temperature is 170 205 F 77 96 C Engine stops if temperature exceeds 221 F 105 C Weld Controls 6 Process Contactor Control Switch See Section 6 3 for Process Contactor Con trol switch information 7 Amperage Range Switch NOTICE Do not switch under load Use switch to select weld amperage range Use the lowest four ranges for Stick and 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 am perage range possible to help prevent arc out ages 8 Voltage AmperageAdjust Control With Process Contactor Control switch in any Stick or TIG setting use control to adjust am perage within range selected by Amperage Range switch With Process Contactor Con trol switch in any MIG position use control to adjust voltage With Voltage Amperage Adjust Control switch item 9 in
47. icon and fault indicator flash To Reset Refuel LOW OIL PRESSURE Engine shuts down when oil pressure is low Display shows LO OIL fault indicator flashes ENGINE SHUTHOWN and wrench is displayed To Reset Push Down on 4 Engine Shutdown switch HIGH COOLANT TEMP Engine shuts down when coolant temperature is high Display shows HI H20 and fault ENGINE SH TDOWN indicator flashes Push down to shut off engine To Reset Push Down on Engine Shutdown switch Note Switch positions are numbered to illustrate that there are three switch positions Actual graphics on front panel will vary 57 570 8 OM 243 907 Page 34 SECTION 7 OPERATING AUXILIARY EQUIPMENT 7 1 120 Volt And 240 Volt Receptacles Generator power is not af fected by weld output 1 120 V 20 A AC GFCI Receptacle GFCI1 2 240V 30A AC Twistlock Receptacle RC1 1 2 Receptacles supply 60 Hz single phase power at weld power speed 3 If a ground fault is detected GFCI Reset button pops out and receptacle does not work Check for faulty tools plugged in LI receptacle Press button to reset GFCH At least once a month run en gine at weld power speed and EB B press test button to verify GFCI U is working properly 3 Supplementary Protector CB1 ri 4 Supplementary Protector CB2 o CB1 protects RC1 and the genera
48. moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines A 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 8 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 703 788 2700 website www cganet com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Char
49. se BO iere Are 190206 Cable Bat Neg 42 In Lg 2 Awg W Clamp amp 375 Rng 1 EE 190207 Cable Bat Pos 45 In Lg No 1 Awg W Clamp amp 406 Rng 1 SO Li Lb eee dan ds 108081 Terminal Protector Battery Post Mtg 2 BI PM 203430 Bracket Battery Holddown 1 40 BATT 190896 Battery Stor 12v 650 Crk 110 Rsv Gp 24 Low Mainte Dry 1 E ME 201006 Bolt J Stl 312 18 X 7 750 Pld 2 m PA ee a 201183 Cover Battery Access 1 Auc sew E 168385 Label Warning Battery Explosion Can Blind 1 44 207193 Panel Engine Extension R h Stainless 1 E EE 206387 Guard Fan Right 2 eee 1 2461 m TA 190992 Keeper Latch Engine Access Door 1 VUA P e AA ed 206604 Channel Stiffener Engine Access 1 KI eu 190126 Latch Paddle Series 20 Stainless 1 A9 a WAG 206999 Label Maintenance D502K 5 4 Kubota 1 DO Kaabang 210736 Door Engine Access Stainless 1 OM 243 907 Page 62 Item Dia Part No Mkgs No Description Quantity Figure 12 1 Main Assembly Continued Doa 189975 Hinge Door Access 180 D
50. 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 1 3 Engine Hazards BATTERY EXPLOSION can injure e Always wear a face shield rubber gloves and protective clothing when working on a battery e Stop engine before disconnecting or connect ing battery cables battery charging cables if applicable or servicing battery e Do notallow tools to cause sparks when working on a battery e Do not use welder to charge batteries or jump start vehicles un less the unit has a battery charging feature designed for this pur pose Observe correct polarity 4 and on batteries Disconnect negative cable first and connect it last Keep sparks flames cigarettes and other ignition sources away from batteries Batteries produce explosive gases during normal operation and when being charged e Follow battery manufacturer s instructions when working on or near a battery BATTERY CHARGING OUTPUT can injure Battery charging feature not present on all models e Have only qualified persons do battery charging work
51. 1 189701 Diode Capacitor Board 1 15 PC9 192224 Circuit Card Assy Display 1 TG demus 134201 Stand off Support Pc Card 312 375w Post amp lock 43 3 17 CB11 CB12 139266 Supplementary Protector Man Reset 1p 15a 250vac 2 mia recte teh Gb dene tes 219873 Harness Control Box Weld Control L h consisting of 1 T MN RC3 158466 Conn Rect Univ 084 12p S 3row Rept Cable Panel Lkg 1 UTEM RC1 135133 Conn Rect Univ 084 9p S 3row Rcpt Cable Panel Lkg 1 AA KE dre DRE 221450 Harness Engine Kubota V3300 consisting of 1 serre ets oed S7 199691 Switch Tgl Spdt 6a 125vac On none mc Spd Term located on EE front panel see Figure 12 3 d ARE i PLG10 150316 Conn Rect Univ 039 6p S 3row Plug Cable Lkg 2 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 243 907 Page 65 F Hardware is common and not available unless listed SD D ec NS i AN Cal RO 4 12 Fig 12 4 804 700 B Figure 12 3 Panel Front w Compo
52. 1 De EE 206242 Fan Rotor Segmented Assy Gen 4 POL TET 049026 Screw M10 1 5x 25 Hex Hd pln 8 8 Pin 10 ste ccs icem nat 083883 Washer Lock 402idx0 7090dx 087t Stl SplitiOmm 10 T mI 080389 Screw 312 18x1 00 Hexwhd 66d Stl Pld Slffmg Tap rw 8 daB B rusa ep eda 206380 Adapter engine 1 Sy EE 083883 Washer Lock 402idx0 7090dx 087t Stl SplitiOmm 4 DOR lode sr gate 049026 Screw M10 1 5x 25 Hex Hd oinggobin cece ee eee 4 OM 243 907 Page 69 Item Dia Part No Mkgs No Description Quantity Figure 12 5 Generator Continued a AD suns aches dereen 191579 Cover Starter Hole 2 Sad 2 Duet ac cont 083883 Washer Lock 402idx0 7090dx 087t Stl SplitiOmm 6 ou Df aad craved ET 172555 Screw M10 1 5 X 50hexhd Pin 8 8pld 6 Uca P Dick kaa S 602159 Screw 312 18 X 75hexwhd 6 nga OO LV VEA 604950 Screw 312 18 X 2 25hexhd Pin Gr God 4 TCU 602211 Washer Lock 318 Id X 0 586 4 osi NEE 139341 Washer Exciter esses hh hen 4 A CEPR 190823 Brush Contact 3 Jew dicet ELLE 208469 Clip Spring EE 3 NNI MET C 189142 Brushholder Assembly Gen
53. 12 6 Main Rectifier Assembly 1 2s O e 193453 Bracket Mtg Box Fer 1 111 PC1 207397 Module Field Current Regulator cece ene ees 1 2m KEE Aer an 203260 Label Caution Do Not Use Ether 1 ea AO raso Na fading e 210726 Stiffener engine access door 2 Ce TVA eue s 233088 Label Danger Using A Generator Indoors Can Kill You In Minutes Unit 1 E LSU P este Tay Ux MEYER RUIT ERR AD 237278 Label Hour Fuel Meter Usage 1 EU 191819 Hose Sae 312 Id X 560 Od X 14 000 1 decus oka Brest qoe TN Sue 095636 Hose Sae 187 Id X 410 Od X 30 000 1 EM 198584 Hose Sae 312 Id X 560 Od X 4 500 1 Nome io eL MM puo Dm 049525 Nut 312 18 U nut Multi thread 10 dono Desire pens 190058 Nut 250 20 U nut Multi thread 2 E RE tae 210738 Kit Label Includes safety and informational labels 1 When ordering a component afiginaliy displaying a precautionary label the label should also be ordered Order label individually or as part of label kit 210 738 Recommended Spare Parts Optional To maintain the factory original performance of your equipment
54. 2 E NEE 071890 Retainer Mount Eng Gen 4 rA OP 071730 Tubing Stl 875 Od X12ga Wall X 2 500 4 uu m 083476 Mount Eng Gen Nprn 875id X 2 5000d X 2 000 60 Dur 4 xa 09 3 aseo ssa se 135205 Nut 625 11 94hex 77h Stl Pld Elastic Stop Nut 4 TCU BEE 207717 Filter Oil Spin On Cartridge Type 1 ial dadas 207715 Filter Fuel Secondary Spin on Cartrige Type 1 poa fi su aA a Figure 12 5 Generator hn 1 KUNAN AS EE 239361 Engine Kubota Del Elec V3300 Consisting Of 1 AER od AE aa PAG ance 206380 Adapter Engine Kubota V3300 See Figure 12 5 1 Mata a Ga deb aco NG O 206907 Plug Assy W Leads Elec Kubota 1 p TEEN 207713 Thermostat 170f 76 5c W Gasket 1 Oo 206379 Flywheel Kubota V3300 1 sew vs esa na 198990 Adapter Oil Pressure Sender 1 Los D vsus S12 187542 Switch Pressure Oil 11psi No Cont Frict Term 1 76 TEMPSNDR 193231 Sender Coolant Temp 300 Deg F 1 2 14 Npt 1 c e EEN 207712 Belt Fan 13 X 1200mm V belt u eee 1 uL B dignus vamos 206390 Hose Radiator Upper
55. 2 cables x 100 ft Use the 200 ft 60 m column to determine cable size EA A Weld Cable Size and Total Cable Copper Length in Weld Circuit i kek Weld Output Not Exceeding Terminals A Turn off power be fore connecting to weld output termi nals 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft amp Do not use worn 100 ft 30m orLess 45m 60m 70m 90m 105 m 120 m damaged under sized or poorly spliced cables 10 QO 60 100 Welding uty Duty 10 100 Duty Cycle Cycle Amperes we Cycle AWG mm mm3 AWG mm 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 0 120 250 2 85 1 50 1 0 60 210 70 4065 4 0 120 Zu CFO 300 1 50 1 0 60 20 70 3 O 95 4 0 120 eU a GE 2x2 2 2 2x4 350 1 0 60 2 0 70 3 0 95 4 0 120 ean ea oo a Ge 2x2 2 2x4 2x4 400 1 0 60 2 0 70 3 0 95 4 0 120 Gab Gob ea yA E 2x2 0 2x3 0 2x4 0 3x3 0 3x3 0 500 2 0 70 3 0 95 4 0 120 2x70 2x95 2x120 3x95 3x95 2x2 0 2x3 0 2x4 0 3x3 0 3x4 0 3x4 0 600 3 0 85 4 0 120 2x70 2x95 2x120 3x95 3x120 3x120 2x3 0 2x4 0 3x3 0 3x4 0 3x4 0 4x4 0 700 4 0 110 2x2 0 2x70 295 2x120 3x95 3x120 3x120 4x120
56. 240V 16 L lt MACHINE WIRE NUMBERS 42 45 10 39 WELD SECONDARY m ge 10 40 79 ENGINE CONTROLS AUN EXCEPT 42 CHASSIS EEG UE ANG int JO 19 80 99 AUX SECONDARY ag 99 SR4 X x x 100 149 EXCITER CONTROL JS er Co E POLARITY SWITCH OPTIONAL WITH THE POLARITY SWITCH OPTION S 19 amp TO THE POLARI WITCH RAT THAN THE OUT STUDS THE OUTPUT 2e aaa STUDS ARE LABELED 7 ELECTRODE AND WORK 79 T Sg A J re bp le el t POSITIVE aag oq P 370 ELECTRODE RECTIFIER WW PROTECTION 1 CG sch PC4 Ee a PCS a gail p N ko t 36 WELD METERS as WORKS S TAG 000097 OPTIONAD SR3 3 i L T JI l T AT E E svat Fi er H P Oe tis 5 FUEL PUMP pa KO e leg m g 45 je be 64 Gio t we zi SF z 2 FUEL LEVEL s8 SENDER TH e 42 TI 61 6 4 Ca 3 7 COOLANT TEMP SENDER 42 TH Mm POSITION Je ST POLARITY Ze AC 7e REV POLARITY 17 JO 19 I N ji N H SR H 1 29 28 237 497 C OM 243 907 Page 49 SECTION 10 RUN IN PROCEDURE 10 1 Wetstacking run int 2007 04 NOTICE Do not perform run in procedure at less than 20 volts weld output and do not exceed duty cycle or e
57. 9 Overload Protection ed ENGINE SHUTDOWN Push down to shut off engine b A Stop engine 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 out put stops 4 kVA kW generator pow er is still available 3 Circuit Breaker CB4 Not Shown 4 Supplementary Protector CB5 5 Circuit Breaker CB10 Not Shown 6 Supplementary Protector CB11 7 Supplementary Protector CB12 8 Supplementary Protector CB13 CB4 protects the welding arc drive dig circuit If CB4 opens the elec trode may stick to the workpiece more frequently during low voltage short arc length conditions CB4 au tomatically 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 CB10 protects the engine battery cir cuit If CB10 opens the engine will not crank CB10 automatically resets when the fault is corrected CB11 protects the control box wiring harness If CB11 opens weld output stops generator power is still avail able CB12 protects the field flashing cir cuit If CB12 opens the generator may not excite at start up and weld and generator power output may not be available CB13 protects the 115 volt AC output to remote recept
58. A VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e est pr f rable de v rifier le liquide de refroi dissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expansion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer com me suivant 2 4 Dangers li s l hydraulique Les QUIPEMENTS HYDRAULIQUES peuvent provoquer des blessures ou m me la mort e Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qua lifi est autoris installer faire fonctionner et r parer cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux Ne pas d passer le d bit nominal ou la capacit de la pompe hydraulique ou de tout quipement du circuit hydraulique Concevoir le circuit hydraulique de telle sorte que la d faillance d un composant hydraulique ne risque pas de provoquer un accident mat riel ou corporel e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis so
59. B7 and to the isolated neutral terminal and grounding termi nal as necessary CB7 protects single phase re ceptacle RC5 and the load wires from overload If CB7 opens all three phase generator output stops and the receptacle does not work Reinstall generator power panel Ref 197 399 802 332 B 803 655 OM 243 907 Page 36 SECTION 8 MAINTENANCE amp TROUBLESHOOTING Maintenance Label 8 1 V 666 907 LZZ0e WIO OLOEZ 0LOOL SOOT JejsouueuL Gb LL 7v oL JeyeM ezeeJjnue 09 05 u LLO 0 L600 0 ww 72 0 EZ O 1sneux3 pue ayeju 4 22 9 03 68t9v XIM 891228d uospjeuoq 866 264 WIO 06797 XIM 692228d Uosp gu0q 666 26 WIO kuondo vLZZ02 WIO OLOEb L8Sc BIoqny enc 21220e NAO 01026 2189 I JOqTJ ut 2 1 uiu EL SHO AUSO9SIA HINN G gt S 30 L 40 Y 10Q 9008 AA a lt a t 8 S26 a WISV ev LW 6982 sa L09 LS NIG 185 sz vz 1 2 66 ei 212207 NAO O tvZE 0LODL Jogny RE ZE os 98 POL 22k do b vL 12 V 39 39 Q0 IdV 40 984 V 099 Wd 0884 a ya 198 peuinbe NZI gt y 1ueuieje E36 19414 AE ugeet ANISNA 135316 95800 A V LOSII
60. ICK position for air carbon arc CAC A CC STICK cutting and gouging with or without CC STICK with remote remote output control on off control CV MIG CV MIG voltage sensing wirefeeder using wirefeeder 14 pin remote control 1 Process Contactor Control Switch See Section 6 1 For Location 242 336 A Section 6 4 Use Weld Terminals Always On CC Stick position for air carbon arc CAC A cutting and gouging A Weld output terminals are energized when Process Contactor Control switch is in a Weld Terminals Always Place switch in Weld Terminals Remotely Controlled positions to turn weld output on and off with a device connected to the re mote 14 receptacle When switch is in a Weld Terminals Always On CC Stick position the arc drive dig circuit provides additional amperage during On position and the engine is running Use switch to select weld process and weld Place switch in Weld Terminals Always On positions for weld output to be on whenever output on off control see table below and the engine is running low voltage short arc length conditions to prevent sticking electrodes The arc drive dig circuit is disabled when switch is in MIG TIG and CC stick With Remote On Off Control positions Process Contactor Control Switch Settings Switch Setting Process Output On Off Control Weld Terminals Remotely Controlled CC TIG GTAW With HF Unit Pulsing Devi
61. LOSED S1 LEAD NUMBERS HEAT OFF HEAT START 30 17 30 19 x 30 50 x X CONTACT CLOSED Sp 120 N_ NNNAN_ AY m LAN Kg D2 B3 Al PC1 FIELD CURRENT REGULATOR K3 Al F3 PLG8 30 PIN PLG9 18 PIN A2 V AN AN C3 D2 D3 K2 F3 J2 RCI 182 lt 7 PLG 3 j 2 s 113 Ko 40 Cem B3 Hi gt gt WA A 131 H2 gt gt gt Ki HE EE FA 125 gt CD J1 L 123 124 S6 MG O Tic STICK 67 C2 19 Ye r S l2 VOLT STARTER xs 114 H D14 GLOW PLUG Figure 9 1 Circuit Diagram For Welding Generator WARNING Te 7 ELECTRIC SHOCK HAZARD e Do not touch live electrical parts Disconnect input power or stop engine before servicing Do not operate with covers removed Have only qualified persons install use or service this unit eed RC5 120
62. OM 243 907G 2011 09 Red D Arc Welderentals D 1 866 RED D ARC reddarc com TIG GTAW Welding MIG GMAW Welding re Flux Cored FCAW Welding d FC pa Air Carbon Arc CAC A Cutting La and Gouging Description CSS Engine Driven Welding Generator D550K HO CC CV DC Diesel Welder OWNER S MANUAL File Engine Drive FA TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 SymbolUsage 1 2 Arc Welding Hazards 1 3 Engine Hazards 1 4 Hydraulic Hazards 1 5 Compressed Air Hazards 1 6 Additional Symbols For Installation Operation And Maintenance 1 7 California Proposition 65 Warnings 1 8 Principal Safety Standards 1 9 EMF Information SECTION 2 CONSIGNES DE S CURIT LI 2 1 Signification des symboles 2 2 Dangers relatifs au soudage l arc RE AVANT UTILISATION 2 3 Dangers existant en relation avec le moteur 2 4 Dangers li s l hydraulique 2 5 Dangers li s l air comprim 2 6 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 2 7 Proposition californienne 65 Avertissements
63. acle RC14 If CB13 opens 115 volt output to RC14 stops Press button to reset supplementary protector Ref 804 582 A 802 170 D Ref 802 313 OM 243 907 Page 44 8 10 Troubleshooting Tables Z at S y EX war A Welding Trouble Remedy No weld output generator power output okay at AC receptacles Place Process Contactor switch S6 in a Weld Terminals Always On position or place switch in a Weld 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 Reset supplementary protector CB11 see Section 8 9 Reset supplementary protector CB5 see Section 8 9 Check for faulty remote device connected to RC14 Check fuse F2 and replace if open see Section 8 9 Check and secure connections to Remote 14 receptacle RC14 see Section 5 13 Have Facotry Authorized Service Agent check connector board PC6 and connections brushes and slip rings field excitation circuit field current regulator board PC1 and the rotor No weld output or generator power out put at AC receptacles Disconnect equipment from generator power receptacles during start up Reset supplementary protector CB12 see Section 8 9 Check fuses F1 and F2 and replace if open see Sec
64. ade inthe NG A 1866 RED D ARC 3 242 336 A 804 582 A OM 243 907 Page 30 6 2 Description Of Front Panel Controls See Section 6 1 ma ZW AS 98 awe A Engine Starting Controls 1 Start Preheat Switch Use switch to start engine and operate glow plug for cold weather starting Engine runs at continuously Turn switch to Preheat position to operate the glow plug and heat the combustion chambers before cranking engine see starting instruc tions following 2 Engine Shutdown Switch Push switch down to stop engine To Start NOTICE Do not use ether to start engine weld power speed E If engine does not start let engine come to a complete stop before attempting restart Above 41 F 5 C turn Start Preheat switch to Preheat position for 5 seconds and then turn Switch to Start position Release Start Preheat Switch when engine starts Below 41 F 5 C Turn Start Preheat switch to Preheat position for 15 seconds and then turn switch to Start Release Start Preheat switch when engine starts To Stop Push Engine Shutdown switch down to stop engine Engine Gauges EF To read gauges with engine off turn Start Preheat switch to Preheat position 3 Engine Fuel Hour Gauge Use meter to monitor engine running time for scheduling maintenance Use gauge to check fuel level Engine stops if fuel level is low To check fuel level when
65. air comprim e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression pneumatique Soutenir l quipement de facon appropri e par un moyen m canique M TAL CHAUD provenant du d cou page ou du gougeage l arc risque de provoquer un incendie ou une explo sion Ne pas d couper ou gouger proximit de produits inflammables e Attention aux risques d incendie tenir un extincteur proximit OM 243 907 Page 12 LES PI CES ET LIQUIDES CHAUDS peuvent provoquer des br lures Ne pas toucher les pi ces chaudes main nue ni laisser des liquides chauds entrer en contact avec la peau e Pr voir une p riode de refroidissement avant d intervenir sur l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s et porter des gants de soudage et des v tements pais pour viter les br lures LU e N utiliser que les pi ces de rechange recommand es par le constructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section L AIR COMPRIM risque de provoquer des blessures ou m me la m
66. alifornia to cause cancer birth defects or other reproductive harm Wash hands after use OM 243 907 Page 6 H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e f notified by the FCC about interference stop using the equipmentat 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 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as micro processors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as
67. 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 equipmentis 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 unavoid able or acci
68. ance de l op rateur 3 Ne pas courber et ne pas entourer les c bles autour de votre corps 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydraulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Maintenir la t te et le torse aussi loin que possible du mat riel du circuit de soudage
69. ans les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial LES FUM ES ET LES GAZ peu vent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxygene provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proxim
70. aulic systems contact the National Fluid Power Association Publications Department 3333 North Mayfair Road Suite 211 Milwaukee WI 53222 3219 phone 414 778 3344 website www nfpa com OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 OSHA Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 phone 301 504 7923 website WWW CpSC gov Applications Manual for the Revised NIOSH Lifting Equation The Na tional Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 phone 1 800 232 4636 website www cdc gov NIOSH 4 Keep head and trunk as far away from the equipment in the welding circuit as possible 5 Connect work clamp to workpiece as close to the weld as possible 6 Do not work next to sit or lean on the welding power source 7 Donot weld whilst carrying the welding power source or wire feeder 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 cu
71. be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province brand wart 2011 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Red D Arc Welderentals 1 866 RED D ARC reddarc com Contact the Delivering Carrier for File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 01
72. brushes and slip rings and field current regulator board PC1 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 8 9 Check engine wiring harness and components OM 243 907 Page 46 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 Air in fuel system See engine manual Engine starts but stops when Start Pre heat switch S1 is released Check coolant level Automatic shutdown system stops engine if engine temperature is too high see Sec tions 5 9 Have Facotry Authorized Service Agent check fuel hour gauge and control relay CR5 Engine hard to start in cold weather Turn Start Preheat switch S1 to Preheat position before starting see Section or 6 1 Ha
73. ce Or Remote Control At Remote 14 Receptacle Weld Terminals Remotely Controlled CC Stick Stick SMAW With Remote On Off At Remote 14 Receptacle Weld Terminals Remotely Controlled CV MIG MIG GMAW At Remote 14 Receptacle Weld Terminals Always On CV MIG MIG GMAW Electrode Hot Stick SMAW Weld Terminals Always On CC Stick Air Carbon Arc CAC A Cutting And Gouging Electrode Hot Weld Terminals Always On CC Scratch Start TIG Scratch Start TIG GTAW Electrode Hot OM 243 907 Page 32 6 4 Remote Voltage Amperage Control KN 1 Remote 14 Receptacle RC14 Connect optional remote control to RC14 see Section 5 13 Example Combination Remote Amperage Control Stick With Remote On Off Control STICK 125 400 TIG 40 330 Panel PROCESS CONTACTOR CONTROL WELD TERMINALS WELD TERMINALS ET STICK 185 525 ALWAYS ON CONTROLLED Remote Set V A Set Remote S GER et Range Control Not Adjust Switch Process Used In Remote Stick Mode In Example Process Stick Using Remote On Off Range 125 to 400 A DC Min 125 DC Max 400 DC Max 400 A DC r Min 125 A DC Adjust Optional Remote Control Example Combination Remote Amperage Control TIG With Remote On Off Control STICK 125 400 PROCESS CONTACTOR CONTROL WELD TERMINALS REMOTELY CONTROLLED STICK 185 525
74. chase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Manufacturer s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at an authorized service facility as determined by manufacturer Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MANUFACTURER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may
75. ctrode Negative DCEN reverse cable connections If equipped with optional Polarity switch or op tional Polarity AC switch connect wire feeder cable to Electrode terminal on left and work cable to Work terminal on right 804 582 242 336 5 11 Connecting Weld Output Cables Tools Needed TC 3 4 in 19 mm A Turn off power before connecting to weld output terminals A Failure to properly connect weld cables may cause excessive heat and start a fire or damage your ma chine Do not place anything between weld BON cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean Correct Weld Cable Connection Incorrect weld Cable Connection Weld Output Terminal Supplied Weld Output Terminal Nut 803 778 B 5 Weld Cable Terminal 6 Copper Bar Remove supplied nut from weld output ter minal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar OM 243 907 Page 27 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
76. curely in place ar 9 e Keep hands hair loose clothing and tools away from movin COMPRESSED AIR can injure or kill Ges 3 T e 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 maint enance and troubleshooting as necessary Reinstall doors panels covers or guards when servicing is finished and before starting engine e Before working on compressed air system turn off and lockout tagout unit release pres Sure and be sure air pressure cannot be acci dentally applied e Relieve pressure before disconnecting or con necting air lines e Check compressed air system components and all connections and hoses for damage leaks and wear before operating unit Do not direct air stream toward self or others e Wear protective equipment such as safety glasses hearing pro tection leather gloves heavy shirt and trousers high shoes and a cap when working on compressed air system e Use soapy water or an ultrasonic detector to search for HOT PARTS can burn e Do not touch hot compressor or air system leak bare hands Do not i t if leak paris tas SHEEP O PES E EES e Allow cooling period before working on equip ment e Reinstall doors panels covers or guards when servicing is finished and before starting unit If ANY air is injected into the skin or
77. d X 875 Od Pltd 6 DE MESE 195911 Endbell Gen Consisting Of 1 Dr P FREE 143220 O ring 2 859 Id X 139CS iaa ees 1 5 AUXSTATOR 214974 Stator Weld Power 1 6 WELD STATOR 254093 Stator Weld Assembly Complete High KVA 1 Arm 225120 Label Warning Moving Parts Can Cause Injury 2 225 EE 190197 Guard Generator Wire Mesh 1 Sep BG vr E 172674 Spring Ext 240 Od X 041 Wire X 3 500pld 2 s MO ooa e qe 191580 Cover Starter Hole 1 xac Dd bie 208216 Spacer Stl Kubota V3300 18ga Generator 1 eae Gaga pa a 039207 Baffle Ar EE e eee BANG EX fouet ia 1 13 ROTOR 251855 Rotor Generator Segmented Assy Includes 1 PE ME 251856 Rotor Generator Includes cece eects 1 aa PIA 024617 Ring Rtng Ext 1 375 Shaft X 050 Thk 1 san Oa aka 053390 Bearing Ball Rdl Sgl Row 1 370 X 2 880 X 6 1 Em Hub Drive Not Sold Separately 1 med 210447 Fan Rotor Assy Generator Segmented includes 1 E EE 210332 Plate Flex Hubmount
78. d frequency 5 Essential Loads Generator output may not meet the electrical requirements of the prem ises If generator does not produce enough output to meet all require ments connect only essential loads pumps freezers heaters etc See Section 11 4 OM 243 907 Page 58 11 11 Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt Loads e A Use GFCI protection when operating auxiliary equipment If unit does not have GFCI receptacles use GFCl protected exten sion cord Current Maximum Allowable Cord Length in ft m for Conductor Size AWG Amperes Load Watts 4 6 8 10 12 14 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 296 voltage drop Cord Lengths for 240 Volt Loads A Use GFCI protection when operating auxiliary equipment If unit does not have GFCI receptacles use GFCl protected exten
79. dental 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 volt age 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 ground and operate this equipment according to its Owner s Manual and national state and local codes EF Indicates special instructions AEN This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols 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 whe
80. dual 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 S 0623 OM 243 907 Page 54 11 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 1HP 6100 1600 1 1 2 HP 8200 2200 2HP 10550 2850 3 HP 15900 3900 5HP 23300 6800 Capacitor Start Capacitor Run 1 1 2 HP 8100 2000 5HP 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 11 6 Approximate Power Requ irements 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
81. ec tion lors d une intervention sur la batterie Arr ter le moteur avant de d brancher ou de brancher des cables de batterie des c bles de chargeur de batterie le cas ch ant ou de batterie d entretien e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser l appareil de soudage pour charger des batteries ou faire d marrer des v hicules l aide de c bles de d marrage sauf si l appareil dispose d une fonctionnalit de charge de batterie destin e cet usage Observer la polarit correcte 4 et sur les batteries e Debrancher le cable n gatif en premier lieu Le rebrancher en dernier lieu e Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces derni res produisent des gaz explosifs en fonctionnementnormal et en cours de charge e Respecter les consignes du fabricant de la batterie pour travailler sur une batterie ou proximit Le COURANT DE CHARGE DE BATTERIE peut provoquer des blessures la fonctionnalit de charge de batterie n est pas disponible sur tous les modeles e Les op rations de charge de batterie ne doivent tre effectu es que par des personnes qualifi es e Ne charger que des batteries plomb acide Ne pas utiliser le chargeur de batterie pour alimenter un autre circuit lectrique basse tension ou pour charger des batteries s ches
82. eeded Bo SEN Right Side A 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 Oil Filter Oil Drain Valve And Hose Oil Fill Cap Fuel Sedimenter Secondary Fuel Filter Fuel Tank Sludge Drain Valve To change oil and filter Route oil drain hose and valve through hole in base See engine manual and engine maintenance label for oil filter change in formation O O1 E ON To drain water from fuel sedimenter Close fuel valve on top of sedimenter Re move bowl and dump water that has col lected in bowl Clean sedimenter filter ac cording to maintenance label To replace secondary 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 clock wise Bleed air from fuel system according to engine manual Inspect fuel line and replace if cracked or worn Close doors ENGINE SHUTDOWN Push down to shut off engine y Ref 800 159 E Ref 802 170 804 583 B To drain sludge from fuel tank A 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 A Properly lift unit and sec
83. eg 2 Dean DUE AX s erus 208141 v gt Bumper DOT aeneus ette ee doceat LA ag PAA 4 SOUS Ee 190190 Tank Coolant Recovery 1 a Det s eodem eai 199298 Panel Rocker Stainless 1 T 191626 Bumper Door Engine Access 2 inc DO acq eee Doa E Rut 199300 Panel Gen Rh Stainless 1 255590 i fes obtentu 206391 Hose Radiator Lower 1 m 199507 Hose Assy Oil Drain 20 lg consisting of 1 may EE 165271 Valve Oil Drain 3 8 18 Nptf 2 c cece eee 1 naa DB NA Sa tained 176529 Ftg Hose Brs Barbed Fem 1 2 Tbg X 3 8 Npt 1 nan NEE 113854 Hose Sae 500 Id X 780 Od Xcoil 1 666 cus OO ceste ten 176528 Ftg Hose Brs Barbed Elbow M 1 2 Tbg X 1 2 Npt 1 i ORDRES 206906 Adapter Oil Drain Fitting 1 n4 PA ees ue te Washer Oil Drain Available Through Engine Manufacturer 1 ida dan Mig cte e 199849 Screw 625 11x4 00 Hex Hd pln Gr5 Pld 4 NAWA MS 071731 Washer Flat 656idx2 2500dx 187t Stl Pld 4 us BD cus sete ho 206396 Bracket Mtg Engine Kubota V3300
84. emettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche Une PRESSION D AIR R SIDUELLE 1 ETDES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures NG e Detendre la pression pneumatique des outils et circuits avant d entretenir ajouter ou changer des accessoires et avant d ouvrir le bouchon de vidange ou de remplissage d huile du compresseur DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher de pieces chaudes du compresseur ou du circuit d air e Pr voir une p riode de refroidissement N avant d intervenir sur l quipement Les PIECES MOBILES peuvent causer wA e Ne pas toucher aux pieces chaudes utiliser les outils des blessures recommand s et porter des gants de soudage et des v tements pais pour viter les br lures Ng e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir fermes et verrouilles les portes panneaux recouvrements et dispositifs de protection LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles B e Avant d intervenir sur le c
85. es lunettes de s curit avec crans lat raux m me sous votre casque Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection gt m LE SOUDAGE peut provoquer un Gis incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Des tincelles et de
86. ew brushes if necessary and check field excitation circuit High output at generator power AC re ceptacles Check engine speed and adjust if necessary see Section 8 6 Have Factory Authorized Service Agent adjust generator power field current resistor R3 Low output at generator power AC re ceptacles Check engine speed and adjust if necessary see Section 8 6 Check fuse F1 and replace if open see Section 8 9 Have Factory Authorized Service Agent check inte grated rectifier SR1 resistor R3 and Capacitor C9 C Three Phase Generator Power Trouble Remedy No or low output at optional three phase generator receptacle RC5 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 8 9 Check engine weld power speed and adjust if necessary see Section 8 6 Have Factory Authorized Service Agent check brushes and slip rings and field current regulator board PC1 High output at optional three phase generator receptacle RC5 Check engine weld power speed and adjust if necessary see Section 8 6 Have Factory Authorized Service Agent check field current regulator board PC1 and PC1 voltage feedback circuit Erratic output at optional three phase generator receptacle RC5 Have Factory Authorized Service Agent check
87. gers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 1 9 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields EMF Welding current creates an EMF field around the welding circuit and welding equipment EMF fields may inter fere with some medical implants e g pacemakers Protective measures for persons wearing medical implants have to be taken For example access restrictions for passers by or individual risk assess ment for welders All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 Keep cables close together by twisting or taping them or using a cable cover 2 Do not place your body between welding cables Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org For Standards about hydr
88. ghtly 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 e 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 OM 243 907 Page 2 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 haz ards 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 Foll
89. hese elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shutoff shielding gas supply when not in use e 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 e 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 e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection AA 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 e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible ti
90. ing Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Battery Chargers CSA Standard C22 2 NO 107 2 01 from Canadian Standards Association Standards Sales 5060 Spectrum Way Suite 100 Ontario Canada L4W 5NS phone 800 463 6727 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 2 9 Informations relatives aux CEM Le courant lectrique qui traverse tout conducteur g n re des champs lectromagn tiques CEM a certains endroits Le courant de soudage cr e un CEM autour du circuit et du mat riel de soudage Les CEM peuvent cr er des interf rences avec certains implants m dicaux comme des stimulateurs cardiaques Des mesures de protection pour les porteurs d implants m dicaux doivent tre prises par exemple des restrictions d acc s pour les passants ou une valuation individuelle des risques pour les soudeurs Tous les soudeurs doivent appliquer les proc dures suivantes pour minimiser l exposition aux CEM provenant du circuit de soudage 1 Rassembler les c bles en les torsadant ou en les attachant avec du ruban adh sif ou avec une housse 2 Ne passe tenir au milieu des c bles de soudage Disposer les c bles d un c t et dist
91. ircuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d but du manuel et dans chaque section d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e N utiliser que les pi ces de rechange recommand es par le e Demander seulement un personnel qualifi d enlever constructeur les dispositifs de s curit ou les recouvrements pour effectuer e Effectuer l entretien en respectant les manuels d utilisation s il y a lieu des travaux d entretien et de d pannage les normes industrielles et les codes nationaux d tat et locaux 2 6 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance LES TINCELLES PROJET ES peuvent provoquer des blessures S Risque D INCENDIE OU h d D EXPLOSION e Ne pas placer l appareil sur au dessus ou A Ska e Porter un cran facial pour prot ger le visage et proximit de surfaces inflammables les yeux e Ne pas installer l appareil proximit de pro e Aff ter l lectrode au tungst ne uniquement duits inflammables la meuleuse dot e de protecteurs Cette ma e Ne pas surcharger l installation lectrique s assurer que l ali noeuvre est ex cuter dans un endroit sir lors mentation est correctement dimensionn e et prot g e avant de que l on porte l quipement homologu de pro mettre l appareil en service tection du visage des mains et du c
92. is unit e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable DE J FALLING EQUIPMENT can injure Use lifting eye to lift unit and properly installed DB FLYING SPARKS can injure accessories only NOT gas cylinders Do not exceed maximum lift eye weight rating see oa e Wear a face shield to protect eyes and face Specifications ad e Shape tungsten electrode only on grinder with e Use equipment of adequate capacity to lift and proper guards in a safe location wearing proper support unit face hand and body protection e If using lift forks to move unit be sure forks are long enough to e Sparks can cause fires keep flammables away extend beyond opposite side of unit e Keep equipment cables and cords away from moving vehicles when working from an aerial location e Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation Publication No 94 110 when manu ally lifting heavy parts or equipment MOVING PARTS can injure e Keep away from moving parts e Keep away from pinch points such as drive rolls 3 OM 243 907 Page 5 WELDING WIRE can injure e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire hU 1 OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before star
93. it d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et for mer des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage genere des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pour prot ger votre visage et vos yeux pendant le soudage ou pour regarder voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter d
94. level drybatt 12008 01 S 0886 OM 243 907 Page 24 5 8 Connecting The Battery A Connect negative battery EU cable last Reinstall cover after connecting battery Tools Needed IF 1 2 in Conn_batt1 2008 02 802 168 E Ref 202 705 802 313 S 0756 C Notes WELD POSITION FLAT HORIZONTAL VERTICAL OVERHEAD WELD JOINT BUTT BUTT TYPES 1G pel BUTT 2G NT N FILLET T JOINT Ref AWS ANSI D1 1 Us Ref 804 248 A OM 243 907 Page 25 5 9 Engine Prestart Checks b GO Check all engine fluids daily Engine must be cold and on a level surface The automatic shutdown system stops en gine if oil pressure is too low or coolant tem perature is too high gt This unit has a low oil pressure shut down switch However some condi tions 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 NOTICE Follow run in procedure in en gine manual If unburned fuel and oil collect in exhaust pipe during run in see Section 10 Fuel NOTICE Do not use gasoline Gasoline will damage engine NOTICE Do not use ether to start engine Add fresh diesel fuel before starting to pre vent air from entering the fuel system see NOTICE Follow run in procedure in engine manu al
95. mes ne pas fumer proximit de liquide hydraulique e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil e Encas de p n tration d un QUELCONQUE liquide dans la peau celui ci doit tre retir chirurgicalement sous quelques heures par un m decin familiaris avec ce type de blessure faute de quoi la gangr ne pourrait appara tre OM 243 907 Page 11 A Les PIECES MOBILES peuvent causer des blessures Ng e S abstenir de toucher des parties mobiles telles que des ventilateurs courroies et rotors e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Ne pas approcher les mains cheveux v tements laches et outils des organes mobiles e Avant d intervenir sur le circuit hydraulique couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit hydraulique ne peut tre remis sous pression par inadvertance e Demander seulement un personnel qualifi d enlever les dispositifs de s curit ou les recouvrements pour effectuer S il y a lieu des travaux d entretien et de d pannage e Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche 2 5 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE ri
96. n 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 e 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 inverter power sources AFTER stopping engine Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can burn e Do not touch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insu SSC lated welding gloves and clothing to prevent burns FLYING METAL or DIRT can injure eyes
97. nents Item Dia Par No Mkgs No Description Quantity Figure 12 3 Panel Front w Components Figure 12 1 Item 107 a EEN Plate Screened Ident Control Order By Model And Serial Number 1 De DU E 236609 Panel Engine Weld Control Stainless 1 nG kasaya St 208278 Switch Range Changeover 1 NG EAD RATE RO E Ce RT a 192558 Harness Range Switch consisting of 1 Med wate RC6 148389 Conn Rect Univ 084 4p S 1row Rcpt Cable Panel Lkg 1 sudo ane R1 193118 Pot Cp Flat 1t 2 W 1k Ohm Linear 1 EE 206809 Harness Weld Control consisting of 1 O chines S6 193234 Switch Rotary 6 Position Gold Contacts 1 SA eer eee tmu 197527 Guard Circuit Breaker For S6 Not Included w Harness 1 OM 243 907 Page 66 Item Dia Part No Mkgs No Description Quantity Figure 12 3 Panel Front w Components Continued mag 70 wanes SD usos 011609 Switch Tgl Spdt 15a 125vac On none on Spd Term Chr 1 Wo tein PLG9 198183 Conn Rect Cinch 18 Pin 1 MA EE KE 196603 Seal Switch 6 Position Rotary 250 Shaft U 1 iang angg PLG14 141450 Conn Rect Metrmate 10skt 1row Plug Cable Lkg 1 pu ees Moa
98. nnecter l quipement avant de SURCHAUFFER L QUIPEMENT arr ter teur ee d ameter le moten P e Laisser l quipement refroidir respecter le fac e Ne pas laisser tourner le moteur trop lentement sous risque d en ei teur de marche nominal dommager le moteur lectrique cause d une tension et d une fr e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste quence trop faibles e Ne pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz S il y a lieu OM 243 907 Page 13 LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes UNE REMORQUE QUI BASCULE peut provoquer des blessures e Utiliser les supports de la remorque ou des blocs pour soutenir le poids e Installer convenablement le poste sur la remor que comme indiqu dans le manuel s y rappor tant LIRE LES INSTRUCTIONS e Lire et appliquer les instructions sur les tiquettes et le Mode d emploi avant l installation l utilisation ou l entretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section e N utiliser que les pi ces de rechange recommand es par le cons
99. nt lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip e Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et chafaudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste OM 243 907 Page 8 F Indique des instructions sp cifiques A cal 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 aff rant pour les actions n cessaires afin d viter le danger souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est recommand Et ne pas tra vailler seul e Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installez mettez la terre et utilisez
100. o 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 Tools Needed QI e Lift 2008 01 804 712 OM 243 907 Page 23 5 6 Installing Exhaust Pipe ar A Stop engine and let cool Point exhaust pipe in desired di rection but always away from front panel and direction of travel ENGINE SHUTDOWN Push down to shut off engine y Tools Needed 3 S 4pin Exhaust 2008 01 Ref 803 604 Ref 202 705 5 7 Activating The Dry Charge Battery If Applicable A 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 electro lyte level If necessary add electro lyte to raise to proper level Reins tall vent caps 4 Battery Charger A Read and follow all instruc tions supplied with battery charger 5 5 Amperes For 30 Minutes Charge Time 6 30 Amperes For 12 Minutes Charge Time Charge battery Disconnect charg ing cables and install battery Tools Needed EF When electrolyte is low add only distilled water to cells to e maintain proper
101. orps e Les tincelles risquent de causer un incendie loigner toute LA CHUTE DE L EQUIPEMENT substance inflammable peut provoquer des blessures e Utiliser l anneau de levage pour lever l appareil et les accessoires correctement install es Les PI CES MOBILES peuvent seuls PAS les bouteilles de gaz Ne pas d causer des blessures passer le poids nominal maximal de l illeton voir les sp cifications e Ne pas s approcher des organes mobiles e Utiliser un quipement de levage de capacit suffisante pour e Ne pas s approcher des points de coincement lever l appareil tels que des rouleaux de commande 5 e Enutilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil e Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur e Suivreles consignes du Manuel des applications pour l quation de levage NIOSH r vis e Publication N 94 110 lors du levage manuelle de pi ces ou quipements lourds LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage LE SURCHAUFFEMENT peut endommager le moteur lectrique T I L EMPLOI EXCESSIF peut e Arr ter ou d co
102. ort e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis Sous pression par inadvertance e D tendre la pression avant de d brancher ou de brancher des canalisations d air e Avant Q utiliser l appareil contr ler les composants du circuit d air comprim les branchements et les flexibles en recherchant tout signe de d t rioration de fuite et d usure Ne pas diriger un jet d air vers soi m me ou vers autrui e Pour intervenir sur un circuit d air comprim porter un quipement de protection tel que des lunettes de s curit des gants de cuir une chemise et un pantalon en tissu r sistant des chaussures montantes et une coiffe e Pour rechercher des fuites utiliser de l eau savonneuse ou un d tecteur ultrasons jamais les mains nues En cas de d tection de fuite ne pas utiliser l quipement e Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de mettre en marche l appareil e En cas d injection d air dans la peau ou le corps demander imm diatementune assistance m dicale L INHALATION D AIR COMPRIM risque de provoquer des blessures ou m me la mort e Ne pas inhaler d air comprim e Utiliser Nair comprim uniquement pour d couper ou gouger ainsi que pour l outillage pneumatique e R
103. ot run engine with out a properly working thermostat and ra diator cap gt To improve cold weather starting Use Engine Start Preheat switch to op erate glow plug 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 in formation Use correct grade oil for cold weather see Section 8 1 OM 243 907 Page 26 5 10 Weld Output Terminals EES ENGINE SHUTDOWN Push down to shut off engine y 1 Positive 4 Weld Output Terminal 2 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 4 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 op tional Polarity AC switch connect electrode holder cable to Electrode 4 terminal on left and work cable to Work terminal on right MIG and FCAW Welding For MIG and FCAW welding Direct Current Electrode Positive DCEP on CC CV models connect wire feeder cable to Positive 4 termi nal on left and work cable to Negative ter minal on right Use Process Contactor switch to select type of weld output see Section 6 3 For Direct Current Ele
104. ot see or smell e NEVER use inside a home or garage EVEN IF doors and windows are open e Only use OUTSIDE and far away from windows doors and vents BATTERY ACID can BURN SKIN and EYES e Do nottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flammables OM 243 907 Page 3 1 4 Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the hydraulic pump or any equipment in the hydraulic system Design hydraulic sys tem so failure of any hydraulic component will not put people or property at risk e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Do not work on hydraulic system with unit running unless you are a qualified person and following the manufacturer s instructions e Do not modify or alter hydraulic pump or manufacturer supplied equipment Do not disconnect disable or override any safety equipmentin the h
105. ow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby n NOISE can damage hearing Noise from some processes or equipment can dam age hearing e Wear approved ear protection if noise level is high ELECTRIC AND MAGNETIC FIELDS EMF can affect Implanted Medical Devices e 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 pres sure 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
106. quipment damage may occur 1 Welding Generator Run diesel engines near rated volt age and current during run in period to properly seat piston rings and prevent wetstacking See name plate 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 addition al engine run in information OM 243 907 Page 50 10 2 Run In Procedure Using Load Bank ra A Stop engine 2 We CI Do not touch hot exhaust pipe engine parts or load bank grid A 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 genera tor auxiliary power receptacle 2 Welding Generator Place A V range switch in maxi mum position A V control in mini mum position
107. r 1 625 Dia X 250 Id W Set Screwsplstc 1 oup octets 215207 Harness Unit Weld Control CV consisting of 1 DAHER deg PLG6 114063 Conn Rect Univ 084 4p S 1row Plug Cable Lkg 1 RR PLG8 198184 Conn Rect Cinch 30 Pin 1 Ra Ke PLG13 147992 Conn Rect Univ 039 10p S 2row Plug Cable Lkg 1 ndun PLG3 158465 Conn Rect Univ 084 12p S 3row Plug Cable Lkg 1 ier are dawn paves 088731 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 TU nbang ees 135873 Clip Conduit Convoluted 1 2 In 6 35mm Mtg Hole 3 eee A AEN CRI dee 187654 Seal Wire Univ 12p S 3row 1 196602 Plug Cavity 18 30 Position Cinch Connector 7 DES INS cp Rates 024103 Blank Snap in Nyl 750 Mtg Hole Black 1 120304 Blank Snap in Nyl 250 Mtg Hole Black 2 Optional When ordering a component originally displaying a precautionary label the label should also be ordered Order label individually or as part of label kit 210 738 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
108. r unit may differ from those shown 11 1 Selecting Equipment e 1 Generator Power Receptacles Neutral Bonded To Frame 2 3 Prong Plug From Case pa O Grounded Equipment i 2 3 2 Prong Plug From Double Insulated Equipment D CS Be sure equipment has double m J insulated symbol and or word ing on it 4 0 fa a UU D 4 0 d 120V MAIN BREAKER A Do not use 2 prong plug un less equipment is double in sulated gen pwr 2011 04 ST 800 577 A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards A Also see AWS Safety A 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 48 AWG or larger insu 1 2 lated copper wire GND PE E Electrically bond generator WA frame to vehicle frame by met TS al to metal contact gt A Bed liners shipping skids and some running gear insu 7 ae 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 A Use GFCI protection when operating auxiliary equip ment If uni
109. rk Connection QOP Alternator With Z Hertz Rectifier Q Ka Contactor On OM 243 907 Page 16 SECTION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Welding Gw Rated Welding ner Ul Generator Power Engine Fuel Mode Range Output Voltage Rating Capacity Three Phase Generator CC DC 20 600A 500A 40 Volts DC 95 Single Phase Three Phase Kubota V3300 B 100 Duty Cycle 12 20 kVA kW 50 48A Water Cooled Four 25 gal CV DC 600 A 44 Volts DC 120 240 VAC 60 Hz Cylinder 49 5 HP Diesel 95 L 14 40V 4096 Duty Cycle 56 In Addition To Standard Engine 4 KVA KW Generator Power 4 2 Dimensions Weights And Operating Angles Dimensions 50 in 1270 mm Height to top of muffler G Wa 28 1 2 in 724 mm mtg brackets turned in Width 30 3 4 in 781 mm o not exceed tilt angles or engine cou l 1 Do not exceed tilt angl ine could mtg brackets turned out be damaged or unit could tip Depth 69 1 2 in 1765 mm A Do not move or operate unit where it could tip A 69 1 2 in 1765 mm B 55 7 8 in 1419 mm Co 46 3 8 in 1178 A D 9 1 2 in 241 mm C E 27 1 2 in 699 mm F 1 in 25 mm G 29 13 16 in 757 mm Je H E 9 16 in 14 mm Dia Hi 1 4 Holes D Front Panel End With mounting brackets in center
110. s de protection Arr ter le moteur avant d installer ou brancher l appareil Lorsque cela est n cessaire pour des travaux d lentretien et de d pannage faire retirer les portes panneaux recouvrements ou dispositifs de protection uniquement par du personnel qualifi Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles Remettre en place les portes panneaux recouvrements ou dispositifs de protection la fin des travaux d entretien et avant de mettre le moteur en marche Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur panneaux LES TINCELLES A L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur LES PIECES CHAUDES peuvent provoquer des br lures e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant de travailler l quipement Ne pas toucher aux pi ces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures L
111. s mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle cable de masse sur la piece le plus pres possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Unefois le travail
112. sque de provoquer des blessures ou m me la mort e Uneinstallation ou une utilisation incorrecte de cet appareil pourrait conduire des d g ts mat riels ou corporels Seul un personnel qualifi est autoris installer utiliser et entretenir cet appareil conform ment son manuel d utilisation aux normes industrielles et aux codes nationaux d tat ou locaux Ne pas d passer le d bit nominal ou la capacit du compresseur ou de tout quipement du circuit d air comprim Concevoir le circuit d air comprim de telle sorte que la d faillance d un composant ne risque pas de provoquer un accident mat riel ou corporel e Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circuit d air ne peut tre mis sous pression par inadvertance e Ne pas intervenir sur le circuit d air comprim lorsque l appareil fonctionne Seul un personnel qualifi est autoris et appliquant les consignes du fabricant e Ne pas modifier ou alt rer le compresseur ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit d air comprim e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Setenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit d
113. system Design compressed air system so failure of any component will not put people or prop erty at risk e Before working on compressed air system turn off and lockout tagout unit release pressure and be sure air pressure cannot be accidentally applied OM 243 907 Page 4 e HYDRAULIC FLUID is FLAMMABLE do not work on hydraulics near sparks or flames do not smoke near hydraulic fluid e Reinstall doors panels covers or guards when servicing is finished and before starting unit e f ANY fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury or gan grene may result e MOVING PARTS can injure e Keep away from moving parts such as fans Ng belts and rotors e Keep all doors panels covers and guards closed and securely in place e Keep hands hair loose clothing and tools away from moving parts e Before working on hydraulic system turn off and lockout tagout unit release pressure and be sure hydraulic pressure cannot be accidentally applied e Have only qualified people remove guards or covers for maint enance and troubleshooting as necessary e Reinstall doors panels covers or guards when servicing is finished and before starting engine HOT PARTS AND FLUID can burn e Do not touch hot parts bare handed or allow hot fluid to contact skin e Allow cooling period before working on equip ment e To handle hot parts
114. t does not have GFCI receptacles use GFCI protected extension cord 800 652 D OM 243 907 Page 53 11 3 Grounding When Supplying Building Systems N3 Bd d O 1 Equipment Grounding Terminal 2 Grounding Cable Use 8 AWG or larger insulated copper wire 3 Ground Device EF Use ground device as stated in electrical codes A Ground generator to system earth ground if supplying power to a premises home shop farm wiring system A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators ST 800 576 B 11 4 How Much Power Does Equipment Require SN VOLTS 115 2 AMPS 4 5 1 Hz 60 6 oN 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 approxi mately six times more power while starting the motor than when running see Section 11 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 run ning power requirement in watts 4 5Ax115V 520W The load applied by the drill is 520 watts Example 2 If three 200 watt flood lamps are used with the drill from Ex ample 1 add the indivi
115. ting to weld again e Do not block or filter airflow to unit N STATIC ESD can damage PC boards P e Puton grounded wrist strap BEFORE handling SS boards or parts Po e Use proper static proof bags and boxes to store move or ship PC boards ya TILTING OF TRAILER can injure gd e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer according to instructions supplied with trailer READ INSTRUCTIONS e Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read the safety information at the beginning of the manual and in each section Use only genuine replacement parts from the manufacturer EI e Perform maintenance and service according to the Owner s Manuals industry standards and national state and local codes 1 7 California Proposition 65 Warnings A 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 amp Safety Code Section 25249 5 et seq gt 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 gt This product contains chemicals including lead known to the state of C
116. tion 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regula tor board PC1 and rotor Erratic weld output Use dry properly stored electrodes Be sure connection to work piece is clean and tight Remove excessive coils from weld cables Check and tighten connections inside and outside unit High weld output Check position of Amperage Range switch S3 and Voltage Amperage Adjust control R1 Check engine speed and adjust if necessary see Section 8 6 Have Factory Authorized Service Agent check field current regulator board PC1 Electrode sticks to the workpiece more frequently during low voltage short arc length conditions Circuit breaker CB4 may be open CB4 automatically resets when the fault is corrected see Section 8 9 Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5 Low weld output Check engine speed and adjust if necessary see Section 8 6 Check fuses F1 and F2 and replace if open see Section 8 9 Have Factory Authorized Service Agent check integrated rectifier SR1 capacitor C9 field current regulator board PC1 and rotor Low open circuit voltage Check engine speed and adjust if necessary see Section 8 6 No remote fine amperage or voltage control Place Voltage Amperage Adjust Control switch S5 in Weld Terminals Remotely Controlled position
117. tive 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 e 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 EXHAUST SPARKS can cause fire e Do not let engine exhaust sparks cause fire e Use approved engine exhaust spark arrestor in required areas see applicable codes HOT PARTS can burn e Do nottouch hot parts bare handed e Allow cooling period before working on equip ment e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn e If possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance section or engine manual e Ifthe engine is warm checking is needed and there is no over flow tank follow the next two statements e Wear safety glasses and gloves and put a rag over radiator cap e Turn cap slightly and let pressure escape slowly before completely removing cap Using a generator indoors CAN KILL YOU IN MINUTES e Generator exhaust contains carbon monoxide This is a poison you cann
118. tomatic Wire Feeders Smith 30 Series Flowgauge and Flowmeter Regulators No Labor Transformer Rectifier Power Sources Water Coolant Systems Integrated 3 2 Years Parts Auto Darkening Helmet Lenses No Labor 4 1 Year Parts and Labor Unless Specified Automatic Motion Devices QCoolBelt and CoolBand Blower Unit No Labor External Monitoring Equipment and Sensors Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Flowgauge and Flowmeter Regulators No Labor RFCS Foot Controls Except RFCS RJ45 Fume Extractors HFUnits CE Plasma Cutting Torches No Labor Induction Heating Power Sources Coolers and Electronic Controls Recorders Load Banks Motor Driven Guns w exception of Spoolmate Spoolguns PAPR Blower Unit No Labor Positioners and Controllers Racks Running Gear Trailers Spot Welders Subarc Wire Drive Assemblies Water Coolant Systems Non Integrated Weldcraft Branded TIG Torches No Labor Wireless Remote Foot Hand Controls and Receivers Work Stations Weld Tables No Labor 5 6 Months Parts Batteries Bernard Guns No Labor Tregaskiss Guns No Labor 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets Cables and Non Electronic Controls M Guns MIG
119. tor winding from overload If CB1 120V 20A 1 60Hz 240 V 20A 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 Maximum output is 2 4 kVA kW from GFCI1 and 4 KVA KW from RC1 Maximum output from all re ceptacles 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 A 4 0 kVA KW 191 624 OM 243 907 Page 35 7 2 Connecting To Three Phase Generator AP AS b b plug before inserting leads Reinstall bushing Rear Of Panel 91 92 Single Phase Power Connection 1 DIS SS Ka Ka J Three Phase Power Connection ACT Single Three Output Phase Phase 17y 3 o Volts 120 240 240 A Close panel opening Amps 50 48 if no connections are KVAJKW 12 20 made to generator Frequency 60 Hz Engine Speed 1850 RPM Lead 42 connects to GROUND stud on front of unit 7 Jumper 42 is connected to 90 at factory 93 91 90 92 Ke 12 A Close panel opening if no connections are made to generator 1 Phase
120. tructeur e Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences OK e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil Effectuer regulierement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement
121. tting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 243 907 Page 7 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre rom 2011 04 A Pour carter les risques de blessure pour vous m me et pour autrui lire appliquer et ranger en lieu s r ces consignes relatives aux pr cautions de s curit et au mode op ratoire Signification des symboles 2 1 DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dangers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les ris ques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 8 Veuillez lire et respecter toutes ces normes de s curit
122. u ils provoquent des cancers des malformations cong nitales ou d autres probl mes de procr ation Se laver les mains apr s utilisation OM 243 907 Page 14 Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des pro duits chimiques dont l tat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et des malformations cong nitales ou autres probl mes de procr ation 2 8 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ins com Safe Practices for the Preparation of Containers and Piping for Welding and Cutting American Welding Society Standard AWS F4 1 from Glob al Engineering Documents phone 1 877 413 5184 website www global ins com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 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 703 788 2700 website www cganet com Safety in Weld
123. uld tip A Always securely fasten weld ing generator onto transport vehicle or trailer and comply with all DOT and other applica ble codes NOTICE Do not install unit where air flow is restricted or engine may overheat See Section 4 2 for lifting eye rating See Section 5 3 for mounting in formation 460 mm installa 2008 01 Ref 800 652 Ref 800 477 A 803 274 804 712 OM 243 907 Page 21 5 3 Mounting Welding Generator Supporting The Unit Using Mounting Brackets Welding Unit In Place Bolting Unit In Place Tools Needed TC 9 16 in A 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 NOTICE Do not mount unit by supporting the base only at the four mounting brackets 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 brack ets 3 1 2in Bolt And Washer Minimum Not Supplied 4 39 8 16x1 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 hard
124. una 50 10 1 Wetstacking er RR REELLE EE KARA DORA BARA NANA EI pe ne meer AE 50 10 2 Run In Procedure Using Load Bank 51 10 3 Run In Procedure Using Resistance Grid 52 SECTION 11 GENERATOR POWER GUIDELINES seeeeeeee nnn 53 SECTION 12 PARTS LIST cue x4 824085 HENNEN NEEN x ARNEL ADARNA RANA EEEL 60 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom 2011 04 A Protect yourself and others from injury read follow and save these important safety precautions and operating instructions 1 A A 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 ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards A A A 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 8 Read and follow
125. ure in a level position Use adequate blocks or stands to support unit while drain ing 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 243 907 Page 42 8 8 Servicing Engine Cooling System pes y ng Ng ar we A Stop engine and let cool 1 Radiator Cap 2 RaAdiator Air Bleed Screw 3 Radiator Drain Cock Drain engine coolant according to procedure in engine manual WS ENGINE SHUTDOWN Push down to shut off engine y 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 A solution of 5096 antifreeze and 5096 water must be used in this engine Do not use 10096 antifreeze or severe damage will occur If changing coolant or if coolant lev el is below bottom of radiator filler neck add coolant as follows Tools Needed I 38 in Remove air bleed screw Add cool ant to radiator until coolant is at bot tom of filler neck This ensures all air is purged from the system Reinstall air bleed screw and radia tor cap Check coolant level in re covery tank see Section 5 9 Capacity w Overflow Tank 10 qt 9 5 L Ref 804 583 A Ref 803 136 OM 243 907 Page 43 8
126. us pression par inadvertance e Ne pas intervenir sur le circuit hydraulique lorsque l appareil fonctionne Seul un personnel qualifi et appliquant les consignes du fabricant est autoris le faire e Ne pas modifier ou alt rer la pompe hydraulique ou les quipements fournis par le fabricant Ne pas d brancher d sactiver ou neutraliser les quipements de s curit du circuit hydraulique e Utiliser uniquement des composants et accessoires homologu s par le fabricant e Setenir l cart de tout point pr sentant un danger de pincement ou d crasement cr par l quipement raccord au circuit hydraulique e Ne pas intervenir sous ou autour d un quipement qui n est soutenu que par la pression hydraulique Soutenir l quipement de facon appropri e par un moyen m canique e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enlever le bouchon L utilisation d un groupe autonome l int rieur PEUT VOUS TUER EN QUELQUES MINUTES Lesfum es d un groupe autonome contient du monoxyde de carbone C est un poison invisi ble et inodore e JAMAIS utiliser dans une maison ou garage m me avec les portes et fen tres ouvertes e Uniquementutiliser PEXTERIEUR loin des portes fen tres et bouches a ration L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et
127. use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 243 907 Page 64 803 203 D Figure 12 2 Control Box Assembly Item Dia Part No Mkgs No 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 Aoi lae DS 046432 Holder Fuse Mintr 250 X 1 250 Panel Mtg 2 DB man Aahh 201077 Control BOX EH EE 1 Ce A 201078 GontroliBox Rh ai Stayed a ea nada wa 1 5 CR1 090104 Relay Encl 12vdc Spst 30a 15vdc 5pin Flange Mtg 1 6 CR2 173069 Relay Encl 12vdc Spdt 30a 20a 5pin Flange Mtg 1 7 D14 C14 189701 Diode Capacitor Board 1 B uo ee aki aN 201079 Cover Control BOX 1 9 CB10 190374 Circuit Breaker Auto Reset 12vdc 40 Amp 1 10 CR5 223710 Relay Encl 12vdc Dpst no 25a 6pin Flange 1 11 SR1 SR2 035704 Rectifier Integ Bridge 40 Amp 800v 2 T2 Liu C9 087110 Capacitor Elctlt 240 Uf 200 Vdc Can 1 39 Di 1 EE 177186 Clamp Capacitor 1 375 Dia 1 14 D1 C
128. ve Factory Authorized Service Agent check glow plug and related wiring 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 8 1 Engine suddenly stops Check fuel level Check oil level Automatic shutdown system stops engine if oil pressure is too low see Sections 5 9 Check coolant level Automatic shutdown system stops engine if engine temperature is too high see Sec tions 5 9 Have Factory Authorized Service Agent check control relay CR2 and fuel solenoid FS1 Engine slowly stopped and cannot be restarted Check fuel level Check engine air and fuel filters see Sections 8 3 and 8 7 See engine manual Battery discharges between uses 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 Engine uses oil during run in period wetstacking occurs Dry engine see Section 10 OM 243 907 Page 47 SECTION 9 ELECTRICAL DIAGRAM PLG1 RC1 PLG14 fee 1 705 So 70r saa m7 101 3 108 106 103 ee 106 87 ZAIN 3 ZAIN 4 119 1062 104 Op gt race 98 gt 9 gt PLG3
129. ware not supplied To Weld Unit In Place Weld unit to truck or trailer only at the four mounting brackets install3 2008 01 803 274 200 864 A 803 231 OM 243 907 Page 22 5 4 Grounding Generator To Truck Or Trailer Frame A Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards A Also see AWS Safety amp Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators A Bed liners shipping skids and some running gear insulate the 1 2 GND PE ox 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 Use GFCI protection when operat ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord 1 2 3 rot grnd2 2011 04 800 652 D Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 8 AWG or larger insulated copper wire gt Electrically bond generator frame to ve hicle frame by metal to metal contact 5 5 Using Lifting Eye ANo 1 Lifting Eye 2 Nut 3 Carriage Bolt Raise lifting eye until it snaps in place Lower lifting eye when not needed T
130. y Element 4 Dust Cap 5 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 8 mm nozzle and keep nozzle at least 2 in 61 mm from inside of element Replace primary ele ment if it has holes or damaged gaskets Reinstall primary element and cap dust ejector down aircleaner1 9 00 ST 153 929 B ST 153 585 Ref S 0698 B OM 243 907 Page 39 8 4 Inspecting Cleaning Optional Spark Arrestor E aa ENGINE SHUTDOWN Push down to shut off engine U A Stop engine and let cool 1 Spark Arrestor Muffler 2 Cleanout Plug Remove plug and remove any dirt covering cleanout hole 3 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 A Stop engine and let cool Reinstall cleanout plug Tools Needed IT 3 8 in Ref 242 336 A 804 582 A 8 5 Checking Generator Brushes E ENGINE SHUTDOWN Push down to shut off engine E Minimum Length 5 8 in 16 mm as
131. ydraulic system e Use only components accessories approved by the manufac turer e Keep away from potential pinch points or crush points created by equipment connected to the hydraulic system e Do not work under or around any equipment that is supported only by hydraulic pressure Properly support equipment by mechanical means HYDRAULIC FLUID can injure or kill e Before working on hydraulic system turn off and lockout tagoutunit release pressure and be sure hydraulic pressure cannot be accidentally applied e Relieve pressure before disconnecting or con necting hydraulic lines e Check hydraulic system components and all con nections and hoses for damage leaks and wear before operating unit e Wear protective equipment such as safety glasses leather gloves heavy shirt and trousers high shoes and a cap when working on hydraulic system e Use a piece of paper or cardboard to search for leaks never use bare hands Do not use equipment if leaks are found 1 5 Compressed Air Hazards COMPRESSED AIR EQUIPMENT can injure or kill e Incorrect installation or operation of this unit could result in equipment failure and personal injury Only qualified persons should install op erate and service this unit according to its Owner s Manual industry standards and na tional state and local codes e Do not exceed the rated output or capacity of the compressor or any equipment in the compressed air
132. ysiques du laitier des flammes ouvertes des tincelles et des arcs Placer les bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut provoquer des blessures e Toujours porter une protection faciale des gants en caoutchouc et v tements de prot

D550K HO Operator manual - Red-D

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