Miller Electric Cbi 801D Users Manual O166941c

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OM-166 941C

July 1999

Processes
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Engine Driven Welding Generator

CBI 801D
(Per NSPR 10202)

Warranty
Effective January 1, 1999
(Equipment with a serial number preface of “KK” or newer)
This limited warranty supersedes all previous manufacturers
warranties and is exclusive with no other guarantees or
warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, warrants to its original retail purchaser that new
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped from factory. 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
date that the equipment was delivered to the original retail
purchaser, or one year after the equipment is sent to the
distributor.
1.

5 Years Parts − 3 Years Labor

2.

3 Years — Parts and Labor

*

*
*
*
*

3.

Original main power rectifiers

Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)

1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*

Motor Driven Guns (w/exception of Spoolmate 185)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
Robots
RFCS Foot Controls
Water Coolant Systems
HF Units
Grids
Spot Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Field Options
(NOTE: Field options are covered under the limited
warranty for the remaining warranty period of the
product they are installed in, or for a minimum of one
year — whichever is greater.)

Limited Warranty shall not apply to:
1.

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.

2.

Consumable components; such as contact tips, cutting
nozzles, contactors, relays, brushes, slip rings, or parts
that fail due to normal wear.

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.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at manufacturers 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 purchase 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.

4.

6 Months — Batteries

5.

90 Days — Parts and Labor

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 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.

MIG Guns/TIG Torches
Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts
Spoolmate 185

brand_warr 9/99

OM-166 941C − 7/99

TABLE OF CONTENTS

Section No.

Page No.

SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.
1-2.
1-3.
1-4.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards Booklet Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
4
5

SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.
2-2.

General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . .

6
6

SECTION 3 − SPECIFICATIONS
3-1.
3-2.
3-3.

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8
8

SECTION 4 − INSTALLATION OR RELOCATION
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Grounding Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
9
9
10
10
10
11
12
14
14

SECTION 5 − AUXILIARY POWER
5-1.
5-2.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
120 Volt Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
15

SECTION 6 − OPERATOR CONTROLS
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.

Ampere Ranges Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Amperage & Voltage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Amperage & Voltage Control Switch . . . . . . . . . . . . . . . . . . . .
Output(Contactor) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Engine Air Cleaner Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Temperature Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Gauge/Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Broken Cooling Belt Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16
16
16
17
17
17
17
17
18
18
18
18
18
18
18
18

SECTION
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.

7 − SEQUENCE OF OPERATION
Shielded Metal Arc Welding (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) . . . .
Air Carbon Arc Cutting And Gouging (CAC-A) . . . . . . . . . . . . . . . . . . .
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19
20
20
20
20
21

SECTION 8 − MAINTENANCE
8-1.
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2.
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3.
Fuel/Water Separator And Sludge Drain Plug . . . . . . . . . . . . . . . . . . .
8-4.
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5.
Battery Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6.
Maintenance-Free Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7.
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8.
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9.
Brushes And Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Ether Starting Aid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-1. Load Bank Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-2. Resistance Grid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .

23
25
26
26
26
27
27
27
28
28
28
29
30
31

SECTION
9-1.
9-2.
9-3.
9-4.
9-5.

9 − TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Battery Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31
31
32
32
33

SECTION 10 − ELECTRICAL DIAGRAMS
Diagram 10-1. Circuit Diagram For Welding Generator . . . . . . . . . . . . . . . . . .

36

SECTION 11 − PARTS LIST
Figure 11-1A. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-1B. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-2. Panel, Front w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-3. Panel, Lower Front w/Components . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-4. Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-5. Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38
42
44
46
48
49

LIST OF TABLES AND CHARTS
Table 3-1. Welding Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Chart 3-1. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Chart 3-2. Air Output Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
Chart 4-1. Fuel Consumption Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
Table 4-1. Weld Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Chart 5-1. AC Power Curve For 120 Volt Terminals . . . . . . . . . . . . . . . . . . . . .
15
Table 7-1. Suggested Electrode Diameter For Amperage Range (CAC-A Only) 20
Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
21
Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate
Various Pneumatic Equipment At Pressure Range 70-90 P.S.I.G. . . . . . . . .
22
Table 8-1. Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
Table 8-2. Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Table 9-1. Weld/Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
Table 9-2. Auxiliary Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Table 9-3. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Table 9-4. Air Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .
34

SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1.

INTRODUCTION

We learn by experience. Learning safety through personal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
others teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Research, development, and field experience have
evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
rules.
Read and understand these safe practices before attempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the particular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause serious injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cutting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete procedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equipment installation, use, and service.
1-2.

GENERAL PRECAUTIONS

Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in
this manual, be sure to consult flux and electrode
manufacturers Material Safety Data Sheets
(MSDSs) for specific technical data and precautionary measures concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes

from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin
burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be worn when
others work overhead.
Flammable hair preparations should not be used by persons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Standard Z49.1 listed in Standards Index. NEVER ventilate
with oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium-bearing and similar materials, when welded (or cut) may produce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-supplied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is removed from the work surface, the area is well ventilated
and, if necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
re-entering it.
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchloroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
OM-166 941 Page 1

atmosphere or where the radiant energy can penetrate
to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated material; misuse of compressed gases and cylinders; and
short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work cannot be moved, move combustibles at least 35 feet away out of reach of sparks and
heat; or protect against ignition with suitable and snugfitting, fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
c. openings (concealed or visible) in floors or walls
within 35 feet may expose combustibles to
sparks
d. combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor’s approval that adequate precautions have been taken.
After work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
been cleaned as described in AWS Standard A6.0,
listed 7 in Standards Index.
This includes: a thorough steam or caustic cleaning (or
a solvent or water washing, depending on the combustible’s solubility) followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipOM-166 941 Page 2

ment as recommended in A6.0. Waterfilling just below
working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT depend on sense
of smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN CYLINDERS, listed 11 in Standards Index.
1. Pressure Regulators
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulator from service immediately for
repair (first close cylinder valve). The following symptoms indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pressure release.
Repair. Do NOT attempt to repair. Send faulty regulators for repair to manufacturer’s designated repair center, where special techniques and tools are used by
trained personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious accident. (See 1-3C.)
ICC or DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, or other markings on a cylinder. It
is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.

Locate or secure cylinders so they cannot be knocked
over.

outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.

Passageways and work areas. Keep cylinders clear of
areas where they may be struck.

Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.

Transporting cylinders. With a crane, use a secure support such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not allow contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to open a
cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinder fittings should never be modified or exchanged.
3.

Hose

Tighten connections. When assembling threaded connections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use a CGA adapter (available from your supplier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulator outlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5.

Pressurizing Steps:

Drain regulator of residual gas through suitable vent before opening cylinder (or manifold valve) by turning adjusting screw in (clockwise). Draining prevents excessive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.

Prohibited use. Never use hose other than that designed for the specified gas. A general hose identification rule is: red for fuel gas, green for oxygen, and black
for inert gases.
Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fittings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose connections. Immerse pressured hose in water; bubbles indicate leaks.
Repair leaky or worn hose by cutting area out and splicing (1-2D3). Do NOT tape.
4.

Proper Connections

Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing

Open cylinder valve slowly so that regulator pressure increases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in following position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfull of Ivory
Liquid* or equivalent per gallon of water). Bubbles indicate leak. Clean off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Remove leaky or defective equipment from service immediately for repair. See User Responsibility statement
in equipment manual.
F.

Leaving Equipment Unattended

Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-166 941 Page 3

1-3.

ARC WELDING

Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in standards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DON’T GET
BURNED; COMPLY WITH PRECAUTIONS.
1.

Protective Clothing

Wear long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-resistant leggings. Avoid outer garments of untreated cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pockets to prevent entry of sparks.
2.

Eye and Head Protection

Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 or denser must be used when welding. Place over
face before striking arc.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3.

Protection of Nearby Personnel

Enclosed welding area. For production welding, a separate room or enclosed bay is best. In open areas, surround the operation with low-reflective, non-combustible screens or panels. Allow for free air circulation, particularly at floor level.
OM-166 941 Page 4

Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
To protect against shock:
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
can not be avoided. Sweat, sea water, or moisture between body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could enable dangerous and possibly lethal currents to flow
through the body.
A voltage will exist between the electrode and any conducting object in the work circuit. Examples of conducting objects include, but are not limited to, buildings, electrical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
off.
1.

Grounding the Equipment

Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 “Safety In Welding
And Cutting.”
When installing, connect the frames of each unit such as
welding power source, control, work table, and water circulator to the building ground. Conductors must be ade-

quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly
fatally. Do NOT GROUND to electrical conduit, or to a
pipe carrying ANY gas or flammable liquid such as oil or
fuel.

ject in contact with the electrode circuit unless
the welding power source is off.
b. Equipment without output on/off control (no
contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar processes may not be equipped with welding power
output on-off control devices. With such equipment the electrode is electrically HOT when the
power switch is turned ON. Never touch the
electrode unless the welding power source is
off.

Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equipment ground lead to the third (live) wire, or the equipment will become electrically HOT-a dangerous condition that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating receptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threeprong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
2.

Electrode Holders

Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3.

Connectors

Fully insulated lock-type connectors should be used to
join welding cable lengths.
4.

Cables

Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5.

Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or
red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while welding. If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source.
F.

Protection For Wearers of Electronic Life Support Devices (Pacemakers)

Magnetic fields from high currents can affect pacemaker operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
1-4.

STANDARDS BOOKLET INDEX

For more information, refer to the following standards or
their latest revisions and comply as applicable:
1.

ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126.

2.

NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402.

3.

OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.

4.

ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

Electrode
a. Equipment with output on/off control (contactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes normally are equipped with devices that permit onoff control of the welding power output. When
so equipped the electrode wire becomes electrically HOT when the power source switch is
ON and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob-

Safety Devices

Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.

Terminals And Other Exposed Parts

Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.

7.

OM-166 941 Page 5

5.

ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.

6.

ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PROCESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.

7.

8.

AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.

9.

NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.

10.

NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269.

11.

CGA Pamphlet P-1, SAFE HANDLING OF
COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association,
1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

12.

CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

13.

NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding
Supply Association, 1900 Arch Street, Philadelphia, PA 19103.

14.

American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR
THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126.

15.

ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.

SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1.

GENERAL INFORMATION AND SAFETY

A. General
Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 − Safety Rules For Operation Of Arc Welding Power Source.

OM-166 941 Page 6

2-2.

SAFETY ALERT SYMBOL AND SIGNAL
WORDS

The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instructions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call attention to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid serious personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equipment.

SECTION 3 − SPECIFICATIONS

Table 3-1. Welding Generator Specifications
Rated Output
At 100%
Duty Cycle

Welding
Range

Maximum
Open-Circuit
Voltage
(OCV)

800 Amperes 100 to 800
At 36 Volts DC Amps DC

Maximum
Engine Speed
(No Load)

Single-Phase
Auxiliary Power
While Welding

1860 RPM

3 kVA/kW 60 Hz
26 Amperes At 120 Volts

95 Volts DC
80 Volts DC
Nominal

Weight
Net

Ship

2150 lbs. 2280 lbs.
(975 kg) (1034 kg)

Conforms with NEMA EW1 (ANSI C87.1), “ELECTRIC ARC WELDING POWER SOURCES,” Class I (100).

47 in.
(1194 mm)

72 in.
(1829 mm)
32 in.
(813 mm)
21/32 in. (16.7 mm)
Dia. All Holes

Inches

Millimeters

A

62-3/8

1584

B

50-1/2

1283

C

46-1/2

1181

D

36

914

E

28-3/16

716

F

13-3/4

349

G

9-3/4

248

H

6-1/8

156

J

29-7/8

759

K

1-1/16

27

A
B
C
E

G

K

J

D

F

H
ST-147 323-B

Figure 3-1. Overall Dimensions And Mounting Hole Locations
OM-166 941 Page 7

3-1.

DUTY CYCLE

The duty cycle of a welding generator is the percentage
of a ten minute period that a welding generator can be
operated at a given output without causing overheating
and damage to the unit. This welding generator is rated
at 100 percent duty cycle when operated at 800 amperes. This means that the welding generator can be operated at 800 amperes continuously without causing
damage to the unit.
3-2.

VOLT-AMPERE CURVES (Chart 3-1)

The volt-ampere curves show the voltage and amperage output capabilities of the welding generator at minimum and maximum of each coarse range. Curves of
other settings fall between the curves shown.
Chart 3-1. Volt-Ampere Curves

and Air Carbon Arc Cutting And Gouging (CAC-A) processes.
The unit is equipped with a four-cylinder, air-cooled,
Deutz diesel engine (F4L-912). The air compressor in
this unit is mounted on the front of the engine, and it operates whenever the engine is running. The compressor
delivers 12 cfm of air at a pressure of 100 psi (see Chart
3-2).
In addition to welding and air compressor operation, this
unit can provide up to 3 kVA/kW of 120 volts (26 amperes) ac electrical power for operating 50/60 Hz or 60
Hz auxiliary equipment while welding.
This unit is specially prepared for operation in harsh and
corrosive environments.
An optional Ether Starting Aid can be provided on the
welding generator and is covered within this Owner’s
Manual.
Chart 3-2. Air Output Curve

SB-168 387

3-3.

DESCRIPTION

This unit is a constant current (CC) dc arc welding generator designed for use with the Shielded Metal Arc
Welding (SMAW), Flux Cored Arc Welding (FCAW),

SB-143 883

SECTION 4 − INSTALLATION OR RELOCATION
IMPORTANT: Unless otherwise specified, all directions, such as left or right, are with respect to the operator facing the welding generator front panel.
4-1.

LOCATION (Figure 3-1)

A proper installation site should be selected for the welding generator if the unit is to provide dependable service
and remain relatively maintenance free.
WARNING: ENGINE EXHAUST GASES can
kill.
• Operate in open, well-ventilated areas or if
operated indoors, vent engine exhaust outside the building.
• Keep engine exhaust vent outlet away from
building air intakes.
OM-166 941 Page 8

CAUTION: RESTRICTED AIRFLOW causes
overheating and possible damage to internal parts.
• Maintain at least 18 inches (457 mm) of unrestricted space on all sides of unit, and keep
underside free of obstructions.
• Do not place any filtering device over the
intake air passages of this welding generator.
Warranty is void if any type of filtering device is
used.

The service life and operating efficiency of this
unit are reduced when the unit is subjected to
extreme levels of dust, dirt, moisture, corrosive
vapors, and extreme heat.

A. Lifting Of Equipment
WARNING: INCORRECT LIFTING will damage internal parts; FALLING EQUIPMENT
can cause serious personal injury and
equipment damage.
• Use lifting eye to lift unit only, NOT gas cylinders, trailer, or any other heavy options, accessories, or devices.
• Use equipment of adequate capacity to lift the
unit.
• Use lift forks at least 42 in. (1067 mm) long.

•

Lift only from engine-end (end opposite front
panel).

B. Trailer Mounting
CAUTION: UNCONTROLLED TILTING OF
TRAILER can result in personal injury or
equipment damage.
• Distribute weight so that trailer tongue weight
is approximately 10% of gross trailer weight.
• Follow trailer manufacturer’s instructions
when mounting welding generator onto
trailer.
OPERATION ON UNLEVEL SURFACE can
cause improper lubrication and result in
severe engine damage.
• Operate unit in an approximately level position.
• See Figure 4-1 for maximum allowable tilt for
proper operation.
• Check crankcase oil level with unit on a level
surface.
Exceeding these limits can cause severe engine
damage and improper operation.

Front
Panel

The mounting location should allow sufficient room to
remove the top cover and side panels for maintenance
and repair functions.
Use a properly fitting cover (optional) over the welding
generator when not in operation to protect the unit from
the environment. Be sure unit is cool before installing
any cover.
C. Spark Arrestor Considerations
WARNING: ENGINE EXHAUST SPARKS can
cause fire.
• Exhaust spark arrestor must be installed in
accordance with local, state, and federal
regulations.
The engine exhaust system on this welding generator is
not equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
Forest or on California Grasslands, brush, or forest covered land (see Section 4442 of California Public Resources Code). For other areas, check your state and
local laws. If a spark arrestor (optional) is desired, contact your dealer/distributor.
4-2.

WARNING: HOT ENGINE PARTS can cause
severe burns.
• If applicable, shut down engine and allow exhaust system to cool before installing exhaust
extension.
1.

Install exhaust extension through top cover
opening, over muffler extension elbow. (Be sure
to face end of extension away from air cleaner;
see Figure 3-1).

2.

Secure exhaust extension to top cover of unit using supplied hardware.

4-3.

CONNECTING THE BATTERY
WARNING: BATTERY ACID can burn eyes
and skin and destroy clothing and other material.
• Wear a face shield and proper protective
clothing when working with batteries.
ABNORMAL VOLTAGE can cause damage
to engine electrical components.
• Do not operate engine without the battery
connected.
• Do not disconnect the battery while the engine is running.

17.5
15
Side View Of Unit

Front
Panel
37.5
45
End View Of Unit

EXHAUST EXTENSION INSTALLATION

Ref. S-0024

Figure 4-1. Allowable Tilt Angles For Welding
Generator Engine
Holes are provided in the base for securing the unit in a
permanent location or to a trailer or transport vehicle.
Figure 3-1 gives overall dimensions and base mounting
hole layout.

IMPORTANT: Be sure the Engine Control switch is in
the OFF position before connecting battery.
This unit is equipped with a maintenance-free battery.
To place the unit in service, remove the left, rear side
panel, connect the negative (−) battery cable to the negative battery terminal, and reinstall the side panel. No
other preparation should be required. If the battery does
not supply enough power to crank the engine, charge
the battery according to Section 8-6.
OM-166 941 Page 9

4-4.

FUEL
WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may
be under pressure.
• Rotate fuel cap slowly and wait until hissing
stops before removing cap.
ENGINE FUEL can cause fire or explosion.
• Stop engine before checking or adding fuel.
• Do not spill fuel; if spilled, wipe up.
• Do not refuel if engine is hot or running.
• Do not refuel near sparks or open flame.
• Do not smoke while refueling.
• Do not fill fuel tank to top; allow 1/2 in. (13
mm) from fuel to tank top for expansion.
• Do not weld on fuel tank.

IMPORTANT: Fill fuel tank up to 1/2 in. (13 mm) from
top with fresh fuel before starting engine the first time.
Rust and corrosion preventative was added to inside of
fuel tank and engine at the factory and could cause
rough engine running if not properly diluted with a full
tank of fresh fuel.
The capacity of the fuel tank is 30 gallons U.S. Measure
(114 liters). See the Engine Manufacturer’s Manual for
fuel recommendations. Chart 4-1 illustrates typical fuel
consumption under specific load conditions. Fuel consumption varies from one engine to another. Different
brands of fuel, operating conditions, condition of the engine, etc., also affect the fuel consumption level.
Keep the fuel tank filled to ensure that the injector system receives an adequate supply of fuel. The fuel cap is
located on the lower front panel, behind the right access
door (see Figure 4-2). If the fuel tank is allowed to empty,
air will enter the system, causing starting problems. The
Engine Manufacturer’s Manual outlines procedures for
air bleeding the fuel system.

lower front panel of this unit (see Figure 4-2). If oil level is
below the lower pointer when engine is running, add oil
according to the recommendations in the Engine Manufacturer’s Manual (F4L-912 engine). The oil cap is located under the access door on the top cover.
IMPORTANT: This engine is equipped with an Oil Pressure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes too
low or oil temperature rises to a level that may cause engine damage, the respective gauge/switch shuts down
the engine. The shutdown oil pressure has been factory
set at 30 psi (207 kPa), and the shutdown oil temperature has been set at 265°F (130°C).
B. Wetstacking Considerations
Wetstacking is an accumulation of unburned fuel and oil
in the exhaust pipe. The engine may use oil and wetstacking may occur during the run-in period if the piston
rings are not seated properly. If oil consumption and
wetstacking occur during run-in period, see Section
8-12.
4-6.

EQUIPMENT GROUNDING TERMINAL

GROUND
This unit is equipped with a grounding terminal for
grounding the generator case. The grounding terminal
is located on the lower front panel (see Figure 4-2).
Since the generator neutral is connected to the frame,
the equipment grounding terminal must be connected to
a proper earth ground. Additionally, comply with all national, regional, and local codes concerning portable
generators for the specific application.

For detailed grounding instructions consult your national, regional, and local codes. If additional information regarding your operating circumstances and/or
4-5.
LUBRICATION (Figure 4-2)
grounding requirements is needed, consult a qualified
A. Oil And Oil Level Indicator
electrician or your dealer. After determining the extent to
which any grounding requirements apply to your parThe engine is shipped with its crankcase filled with SAE
20 break-in oil. An oil level indicator is provided on the
ticular situation, follow them explicitly.
Chart 4-1. Fuel Consumption Curve

SB-168 472

OM-166 941 Page 10

4-7.

WELD OUTPUT CONNECTIONS (Table 4-1
And Figure 4-2)

B. Weld Cable Preparation
1.

Install electrode holder to cable following manufacturer’s instructions. Always use an insulated
electrode holder to ensure operator safety.

2.

Install correct size lugs onto ends of both cables
for connecting to work clamp, electrode holder or
wire feeder, and weld output terminals.

3.

Install work clamp onto cable.

RATED WELD OUTPUT

To obtain full rated output from this unit, it is necessary to
select, prepare, and install proper weld cables. Failure
to comply in any of these areas may result in
unsatisfactory welding performance.

C. Weld Output Connections

A. Weld Cable Selection

POSITIVE

Use the following guidelines to select weld cables:
1.

2.

3.

4.

−

+

Use the shortest possible cables, and place
cables close together. Excessive cable lengths
may reduce output or cause unit overload due to
added resistance.

WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.

Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-circuit voltage (ocv) of the welding generator (see
Table 3-1 for unit maximum ocv rating).
Select weld cable size according to maximum
weld output and total length of connecting cables
in weld circuit. For example, if a 25 foot (7.5 m)
wire feeder or electrode holder cable is used with
a 25 foot (7.5 m) work cable, select the cable size
recommended in Table 4-1 for 50 feet (15 m).

NEGATIVE

•

Stop engine, and disconnect negative (−) battery cable before making any weld output
connections.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
1.

Do not use damaged or frayed cables.

Open and secure the lower front panel access
door, and route weld cables through bracket on
front upright to the weld output terminals (see
Figure 4-2).

Table 4-1. Weld Cable Size*
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less

150 ft
(45 m)

Welding
Amperes

10 To 60%
Duty Cycle

60 Thru 100%
Duty Cycle

100

4

4

4

150

3

3

200

3

2

250

2

300
350
400

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
(105 m)

400 ft
(120 m)

10 Thru 100% Duty Cycle
3

2

1

1/0

1/0

2

1

1/0

2/0

3/0

3/0

1

1/0

2/0

3/0

4/0

4/0

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

600

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

700

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

4-4/0

800

4/0

2-2/0

2-3/0

2-4/0

3-4/0

3-4/0

4-4/0

4-4/0

900

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

4-4/0

4-4/0

*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.

S-0007-D

OM-166 941 Page 11

2.

For Shielded Metal Arc Welding (SMAW) and Air
Carbon Arc Cutting and Gouging (CAC-A) (Electrode Positive/Reverse Polarity), connect weld
cables as follows:

4-8.

REMOTE CONTROL CONNECTIONS

A. Remote 9 Receptacle Information
Connections (Figures 4-2 And 4-3)

And

REMOTE 9

a. Connect one end of work cable to NEGATIVE
(−) weld output terminal.

FEEDER
b. Connect end of electrode holder cable to POSITIVE (+) weld output terminal.

A/V

IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
3.

4.

For Wire Feeding Processes (GMAW, FCAW,
SAW) (Electrode Positive/Reverse Polarity),
connect weld cables as follows:

AMPERAGE/
VOLTAGE

OUTPUT
(CONTACTOR)
REMOTE 9 receptacle RC3, located under the lower
front panel access door (see Figure 4-2), is provided to
connect any of the following equipment to the welding
generator circuitry:

a. Connect one end of work cable to NEGATIVE
(−) weld output terminal.

a. Remote Contactor

b. Connect end of electrode holder cable to POSITIVE (+) weld output terminal and remaining
end to terminal on the wire feeder drive housing
(see wire feeder Owner’s Manual for location).

c. Wire feeder which provides contactor control to
the welding generator.

Close and secure front panel access door.
Circuit Breaker CB3

b. Remote Amperage or Voltage control

d. Combination of the above.
To Make connections, align keyway, insert plug, and rotate threaded collar fully clockwise.

Terminal
Strip 3T

Circuit Breaker CB1
(see Section 9-3)

Remote 9
Receptacle
Equipment
Grounding
Terminal

Oil Level
Indicator

Strain Relief
Fuel Cap

POSITIVE (+)
Weld Output
Terminals

NEGATIVE (−)
Weld Output
Terminals

Figure 4-2. Lower Front Panel Components And Connections

OM-166 941 Page 12

Ref. ST-147 322-E

If supplied remote control cord is not suitable for connecting to the REMOTE 9 receptacle RC3, proceed with
one of the following alternatives;
1.

2.

G

I

B. REMOTE Terminal Strip 3T Information And
Connections (Figures 4-2 And 4-4)
WARNING: ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.
• Do not touch live electrical parts.

•

Stop engine, and disconnect negative (−)
battery cable from battery before making any
internal inspection or connections.
• Do not connect to REMOTE 9 receptacle and
terminal strip at the same time.
Since the OUTPUT (CONTACTOR) can be energized from either the receptacle or terminal
strip, it is vital to use only one remote control
method.
MOVING PARTS can cause serious injury.
Keep away from moving parts such as fans,
belts, and rotors.

•

Terminal strip 3T, mounted on the lower front panel (see
Figure 4-2), is included in case the plug supplied on the
remote control cord is not suitable for connections to the
REMOTE 9 receptacle RC3.
To make connections, proceed as follows:
1.

Remove existing plug from remote control cord.

2.

Open and secure lower front door.

3.

Locate strain reliefs provided on lower front panel
(see Figure 4-2).

4.

Insert leads from cord through strain relief.

5.

For Remote Electrical Cutoff Switch, remove
jumper link between terminals N and P.

6.

Connect leads to terminal strip 3T using terminal
information provided in Section C.

7.

Secure the cord in the strain relief.

8.

Close and secure door.

C. Socket/Terminal Information (Figure 4-4)
The following lists the functions of the sockets of REMOTE 9 receptacle RC3 (see Figure 4-3), and the terminals of strip 3T (see Figure 4-4). The following socket/
terminal information is provided in case it is necessary to
wire the auxiliary equipment cord.

E
D

H

Wire a plug or cord to interface with REMOTE 9
receptacle RC3 using socket information in Section C.
Wire remote control cord directly to terminal strip
within unit according to Section B.

F

A

C
B
Ref. S-0706

Figure 4-3. Front View Of Remote 9 Receptacle
With Socket Locations
Socket A/Terminal A:
Contact closure to Socket B/Terminal B
completes the 115 volts ac contactor control circuit; protected by circuit breaker
CB3.
Socket B/Terminal B:
Contactor closure to Socket A/Terminal A
completes the 115 volts ac contactor control circuit.
Socket H/Terminal J:
Command reference; +10 volts dc.
Socket F/Terminal G:
Control circuit common.
Socket G/Terminal H:
Input command signal from wiper of remote control potentiometer; 0 volts equals
machine minimum; +10 volts equals machine maximum.
Socket C/Terminal C:
115 volts ac circuit common; also connected to welding power source chassis.
Socket D/Terminal D:
Up to 10 amperes of 115 volts ac, 60 Hz,
with respect to terminal C (circuit
common).
Terminals L and M of 3T:
Terminals supply 30 amperes of 115 volts
ac, 60 Hz, auxiliary power. Terminal L is
circuit common.
Terminals E/Terminal E or F:
Weld
Voltage
Feedback.
Polarity
determined by connection at terminal E (+)
or F (−).
Terminal N and P of 3T:
Closed circuit between terminals N and P
is normal condition. Open circuit between
terminals N and P is Remote Emergency
Electrical Cutoff condition.
Terminal I/Terminal K:
Machine chassis (Equipment Ground).
OM-166 941 Page 13

4-9.

AIR COMPRESSOR CONNECTIONS

This unit delivers 12 cfm of air at a pressure of 100 psi
whenever the engine is running. A 1/2 in. NPT fitting for
air compressor connections is provided on the top cover
of the unit.
To make connections to the air compressor, obtain and
install a quick-connect connector onto the air compressor fitting.

IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these areas, the system may not work.
1.

Open and secure right rear side door.

2.

If applicable, remove protective cap from ether
valve, or remove old ether cylinder from unit.

3.

Loosen cylinder clamp, install ether cylinder, and
tighten clamp.

4-10. ETHER STARTING AID (Optional)
This unit is shipped without the ether cylinder. Before
this device is operational, an ether cylinder must be obtained and installed. To install the ether cylinder, proceed as follows:
WARNING: IMPROPER HANDLING OR EXPOSURE TO ETHER can seriously harm
your health.
• Follow the manufacturer’s safety instructions
on the cylinder when handling ether components.

IMPORTANT: After installing or replacing ether cylinder, do not use or test ether start system for at least 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
4.

Using a liquid soap and water solution, check all
ether start system connections for leaks. If a leak
exists, escaping gas will produce bubbles in the
solution.

5.

Close and secure side door.

Ref. ST-164 613-A

Figure 4-4. Terminal Strip 3T Information

OM-166 941 Page 14

SECTION 5 − AUXILIARY POWER

POWER OUTPUT
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
• Do not touch live electrical parts.

•
•

Stop the engine and disconnect negative (−)
battery cable from battery before making internal inspection or reconnection.
Ground generator as required by any applicable national, state, and local electrical codes.

The generator neutral is connected to the frame;
therefore, the equipment grounding terminal
must be connected to a proper earth ground.
• Do not connect to any electrical distribution
system normally supplied by utility power unless a proper transfer switch and grounding
procedure are employed.
• Keep away from moving parts such as fans,
belts, and rotors.
• Keep all covers and panels in place while operating.
Warranty is void if unit is operated with any portion of the outer enclosure removed.
ELECTRIC SPARKS can cause fire.
• Disconnect weld cables when using auxiliary
power.
The weld output terminals are electrically energized when the engine is running and the contactor (if applicable) is energized.
• Watch for fire.

•

A brief period (less than 5 seconds) of large current draw
is required for starting motor-driven equipment. This
generator can supply 25% of rated current output at the
terminal strip for motor starting. Disconnect motor from
generator before starting engine. Use adequate size
cords so that voltage drop at the motor is not excessive.
Voltage drops significantly when starting motor-driven
equipment.
Ground fault circuit interrupters (GFCI) may be required. Check local and state codes, and the latest issue
of the National Electrical Code.
5-2.

120 VOLT TERMINALS (Chart 5-1, And
Figure 4-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−)
battery cable from battery before beginning
this installation.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT SURFACES can cause severe burns.
• Wear protective gloves and clothing when
working near a hot engine.
• Allow components to cool completely before touching.

IMPORTANT: All directions, such as left or right, are
with respect to the operator facing the welding generator
front panel. Retain all hardware removed during this
procedure for reinstallation unless specifically told
otherwise.
Chart 5-1. AC Power Curve For 120 Volt Terminals

Have a fire extinguisher nearby, and know
how to use it.

LOW VOLTAGE AND FREQUENCY can damage electrical equipment.
• Turn off or unplug all electrical equipment
connected to auxiliary power before starting
or stopping the engine.
When starting or stopping, the engine has low
speed which causes low voltage and frequency.

5-1.

GENERAL

Calculate load requirements before connecting equipment to the auxiliary power terminals on terminal strip
3T. For best performance (voltage and frequency regulation), limit connected load to approximately 90% of
generator capability.

SB-109 365-B

OM-166 941 Page 15

A. Auxiliary Equipment Connections To Terminal
Strip 3T (Figure 4-2)
WARNING: Read and follow safety information at beginning of entire Section 5-2
before proceeding.
Terminal strip 3T is provided to directly wire the auxiliary
power cord(s) into the unit. To make connections, proceed as follows:
1.

Remove plug from auxiliary equipment cord(s), if
applicable.

2.

Open and secure lower front door.

3.

Locate three strain reliefs on lower front panel.

4.

Insert leads from cord(s) through a strain relief.

5.

Connect leads to terminal strip 3T using terminal
information provided in Figure 4-4.

6.

Secure the cord(s) in the strain relief(s).

7.

Close and secure door.

B. Protection
Circuit breaker CB1 protects the 120 volts ac auxiliary
power terminals from overload. See Section 9-3 for CB1
location and resetting procedure.

SECTION 6 − OPERATOR CONTROLS
Amperage &
Voltage Adjustment
Control

Service Engine
Air Cleaner
Light

Remote Amperage &
Voltage Switch

Output
(Contactor)
Switch
Check Alternator
Light
Engine Control
Switch

Voltmeter

Ammeter

Fuel Gauge

Battery Ampere
Gauge
Ampere
Ranges
Switch

Engine Hours
Meter

Oil Temperature
Gauge/Switch

Oil Pressure
Gauge/Switch

Ref. ST-147 322-E

Figure 8-1. Operator Controls
6-1.

AMPERE RANGES SWITCH (Figure 6-1)

The Ampere Ranges switch provides two coarse amperage ranges. When in LOW OUTPUT, amperage
range is 100-350 amperes. When in HIGH OUTPUT,
amperage range is 300-800 amperes.
CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the Ampere
Ranges switch while welding or under load.
Arcing causes the contacts to become pitted
and eventually inoperative.
6-2.

The AMPERAGE & VOLTAGE ADJUSTMENT control
adjusts welding amperage within range selected by Ampere Ranges switch.The scale surrounding the control
is calibrated in percent and does not indicate an actual
amperage or voltage value.
IMPORTANT: The AMPERAGE & VOLTAGE ADJUSTMENT control may be adjusted while welding.
6-3.

ENGINE CONTROL SWITCH (Figure 6-1)

AMPERAGE & VOLTAGE ADJUSTMENT
CONTROL (Figure 6-1)

A/V

AMPERAGE AND VOLTAGE
ADJUSTMENT
OM-166 941 Page 16

The Engine Control switch has three positions: START,
RUN, and OFF.

A. START Position

If remote amperage or voltage is not desired, place the
AMPERAGE & VOLTAGE switch in the PANEL position. Only the AMPERAGE & VOLTAGE ADJUSTMENT control will adjust output.

Rotating the switch to the START position starts the engine. Release the switch as soon as the engine starts,
and the switch automatically returns to the RUN position.

6-5.

SWITCH

(Figure

ON

B. RUN Position

REMOTE
RUN

OUTPUT
(CONTACTOR)

When the Engine Control switch is in the RUN position,
engine speed remains at governed weld/power speed
(1860 rpm).

WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch the output terminals when the
contactor is energized.
• Do not touch welding wire or electrode and
work clamp at same time.
When the OUTPUT/CONTACTOR switch is in
the ON position, open-circuit voltage is present
at the weld output terminals for as long as the
engine is running.

C. OFF Position

Rotating the Engine Control switch to the OFF position
disconnects battery voltage, thereby shutting down the
engine.
6-4.

OUTPUT(CONTACTOR)
6-1)

REMOTE AMPERAGE & VOLTAGE CONTROL SWITCH (Figure 6-1)

PANEL
REMOTE

A/V
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Do not touch the output terminals when the
contactor is energized
• Do not touch welding wire or electrode and
work clamp at same time.
If remote amperage or voltage control is desired, make
connections to the REMOTE 9 receptacle terminal strip
according to Section 4-8, and place the AMPERAGE &
VOLTAGE switch in the REMOTE position. When a Remote Amperage or Voltage Control is being used, the remote control functions as a fine amperage or voltage adjustment for the AMPERAGE & VOLTAGE ADJUSTMENT control on the welding generator. For example, if
the AMPERAGE & VOLTAGE ADJUSTMENT control
on the welding generator is set at midrange, the Remote
Amperage or Voltage Control will provide (from minimum to maximum adjustment) fine amperage or voltage
adjustment of one half of the welding generator output
for the range selected. For complete remote control of
the output, rotate the AMPERAGE & VOLTAGE ADJUSTMENT control to the maximum position.

If the OUTPUT(CONTACTOR) switch is in the ON position, open-circuit voltage will be present at the output
terminals whenever the engine is running.
If remote contactor control by means of a wire feeder or
remote device is desired, make connections to the REMOTE 9 receptacle or terminal strip 3T according to
Section 4-8, and place the OUTPUT(CONTACTOR)
switch in the REMOTE position. Open-circuit voltage is
present at the weld output terminals whenever the gun
switch or remote device is closed.
6-6.

SERVICE ENGINE AIR CLEANER LIGHT
(Figure 6-1)

This unit is equipped with an engine air cleaner. When
the SERVICE ENGINE AIR CLEANER light PL1 comes
on, the air cleaner requires servicing (see Section 8-2).
6-7.

CHECK ALTERNATOR (Figure 6-1)

The CHECK ALTERNATOR light PL3 comes on if the alternator requires servicing. If the light comes on, check
for loose or broken engine belt.
6-8.

HOUR METER (Figure 6-1)

This unit is equipped with an hour meter. The meter, labeled ENGINE HOURS, registers the total hours of engine operation. This information is useful for routine
maintenance on the engine.
OM-166 941 Page 17

6-9.

FUEL GAUGE (Figure 6-1)

6-13. BATTERY GAUGE (Figure 6-1)

+
BATTERY

FUEL
The FUEL Gauge indicates the level of fuel remaining in
the fuel tank. The unit is equipped with a 30 gallon (114
L) fuel tank.
6-10. MAGNETIC SHUTDOWN SWITCH
An internal switch automatically shuts down the engine
if oil pressure drops to an unsafe level or oil temperature
becomes too high.
The switch assembly is located directly behind the upper front panel access door, in the upper left corner. The
switch is protected by a fuse located on the bottom of the
switch assembly. Should this fuse open, the engine
would not start. See Section 9-3 for fuse replacement
procedure.
6-11.

OIL TEMPERATURE GAUGE/SWITCH (Figure 6-1)

The BATTERY voltmeter registers the alternatorsupplied output voltage to the battery. The meter should
always register 12-15 volts dc while the engine is running. If the voltage is outside this range, stop the engine,
and determine the cause. Do not operate the engine until the trouble has been corrected.

6-14. METERS (Figure 6-1)
The meters are provided to monitor the welding operation; however, they are not intended for exact amperage
or voltage measurements. These meters are internally
connected to the output circuit.
The voltmeter indicates the voltage at the weld terminals, but not necessarily the actual voltage at the welding arc (due to cable resistance, poor connections, etc.).
The ammeter indicates the amperage output of the unit.

6-15. BROKEN
SWITCH

The OIL TEMPERATURE gauge/switch registers the
temperature of the oil in the lubricating system. If the oil
temperature rises to a level that may cause engine damage (factory set at 265°F, 130°C), switch closes and
magnetic shutdown switch stops the engine (see Section 6-10).
6-12. OIL PRESSURE GAUGE/SWITCH (Figure
6-1)

COOLING

BELT

SHUTDOWN

An internal switch automatically shuts down the engine
if the cooling belt breaks. The cooling belt is located on
the rear of the engine. If the engine shuts down, check
for broken cooling belt.

6-16. ETHER STARTING AID (Optional)
The cold weather starting components provide a means
of applying a premeasured portion of ether into the manifold. The amount of ether supplied should be sufficient
to permit easy engine starting under cold weather conditions.
Depressing ETHER STARTING AID switch for one second while cranking the engine will provide the proper
amount of ether to the manifold. This control will function
only while cranking the engine.

The OIL PRESSURE gauge/switch registers the lubricating system pressure in pounds per square inch (psi).
The pressure registered by the gauge should remain
constant for a given engine speed. Should the pressure
fluctuate or drop, stop the engine, and do not operate
until the trouble has been corrected. If the oil pressure
drops to a level that may cause engine damage, switch
closes and magnetic shutdown switch stops the engine
(see Section 6-10). The shutdown oil pressure is factory
set at 30 psi (207 kPa). Normal operating pressure is approximately 50 psi (345 kPa).
OM-166 941 Page 18

CAUTION: ETHER INJECTION WHILE ENGINE IS RUNNING can cause engine damage.
• Do not actuate ETHER STARTING AID while
engine is running.

IMPORTANT: Ether is sprayed into the engine when
this switch is released. Depressing the switch does not
spray the ether into the engine but rather fills the valve
chamber.

SECTION 7 − SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
• Do not touch live electrical parts.
• Stop the engine and disconnect negative (−)
battery cable from battery before inspecting
or servicing.
• Keep away from moving parts such as fans,
belts, and rotors.
• Keep all covers and panels in place while operating.
Warranty is void if the welding generator is operated with any portion of the outer enclosure removed.

7-1.

ARC RAYS can burn eyes and skin; NOISE
can damage hearing.

•
•

Ventilate to keep from breathing fumes and
gases.
• If ventilation is inadequate, use approved
breathing device.
• Use in open, well ventilated areas or vent exhaust out of doors.
HOT METAL, SPATTER, SLAG, and EXHAUST can cause fire and burns.

•
•
•

Watch for fire.
Have a fire extinguisher nearby, and know
how to use it.
Allow work and equipment to cool before handling.

ENGINE FUEL can cause fire or explosion.

•
•
•
•
•
•

Stop engine before checking or adding fuel.
Do not spill fuel; if spilled, wipe up.
Do not refuel if engine is hot or running.
Do not refuel near sparks or open flame.
Do not smoke while refueling.
Do not fill tank to top; allow room for expansion.

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

•

WARNING: Read and follow safety information at beginning of entire Sections 5 and 7
before proceeding.
1.

Install and connect unit according to Section 4.

2.

Wear dry insulating gloves and clothing.

3.

Connect work clamp to clean, bare metal at
workpiece.

4.

Select proper electrode.

5.

Set Ampere Ranges switch and rotate AMPERAGE & VOLTAGE ADJUSTMENT control to the
desired position (see Sections 6-1 and 6-2).

6.

If remote amperage control is not used, place
AMPERAGE & VOLTAGE switch in the PANEL
position. If remote amperage control is to be
used, place AMPERAGE & VOLTAGE switch in
the REMOTE position.

7.

If remote contactor control is not used, place
OUTPUT(CONTACTOR) switch in the ON position. If remote contactor control is to be used,
place OUTPUT(CONTACTOR) switch in the REMOTE position.

8.

Start engine as instructed in Section 7-6.

9.

Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.

10.

Place Engine Control switch in the RUN position.

11.

Energize auxiliary equipment, if applicable.

12.

Wear welding helmet with proper filter lens according to ANSI Z49.1.

13.

Insert electrode into electrode holder.

14.

Begin welding.

Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm
your health.

Wearers should consult with their doctor before going near arc welding, gouging, or spot
welding operations.

See Section 1-Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.

SHIELDED METAL ARC WELDING (SMAW)

7-2.

GAS METAL ARC (GMAW) AND FLUX
CORED ARC WELDING (FCAW)
WARNING: Read and follow safety information at beginning of entire Sections 5 and 7
before proceeding.

1.

Install and connect unit according to Section 4.

2.

Install and connect wire feeder to the terminal
strip according to wire feeder Owner’s Manual
and Section 4-8.

3.

Wear dry insulating gloves and clothing.

4.

Connect work clamp to clean, bare metal at
workpiece.

5.

Set Ampere Ranges switch and rotate AMPERAGE & VOLTAGE ADJUSTMENT control to the
desired position (see Section 6-1 and 6-2).
OM-166 941 Page 19

6.

7.

If remote amperage or voltage control is not
used, place AMPERAGE & VOLTAGE switch in
the PANEL position. If remote amperage or voltage control is to be used, place AMPERAGE &
VOLTAGE switch in the REMOTE position.

Table 7-1. Suggested Electrode Diameter For
Amperage Range (CAC-A Only)
Amperage Range

Electrode Diameter
Inches

Millimeters

Minimum

Maximum

1/8

3.2

30

60

5/32

4.0

90

150

3/16

4.8

200

250

1/4

6.4

300

400

If remote contactor control is not used, place
OUTPUT(CONTACTOR) switch in the ON position. If remote contactor control is to be used,
place OUTPUT(CONTACTOR) switch in the REMOTE position.

8.

Turn on shielding gas supply, if applicable.

5/16

7.9

350

450

9.

Start engine as instructed in Section 7-6.

3/8

9.5

450

600

Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.

1/2

12.7

800

1000

5/8

15.9

1000

1250

11.

Place Engine Control switch in the RUN position.

3/4

19.0

1250

1600

12.

Energize auxiliary equipment, if applicable.

1

25.4

1600

2200

13.

Wear welding helmet with proper filter lens according to ANSI Z49.1.

10.

14.

7-3.

Begin welding.

AIR CARBON ARC CUTTING AND GOUGING
(CAC-A) (Table 7-1)
WARNING: Read and follow safety information at beginning of entire Sections 5 and 7
before proceeding.

1.

Install and connect unit according to Section 4.

2.

Wear dry insulating gloves and clothing.

3.

Connect work clamp to clean, bare metal at workpiece.

4.

7-4.

Place AMPERAGE & VOLTAGE switch in the
PANEL position.

5.

Place OUTPUT(CONTACTOR) switch in the ON
position.

6.

Set Ampere Ranges switch and rotate AMPERAGE & VOLTAGE ADJUSTMENT control to the
desired position (see Sections 6-1 and 6-2).

7.

Start engine as instructed in Section 7-6.

8.

Connect desired auxiliary equipment to the 120
volts ac terminals according to Section 5.

9.

Place Engine Control switch in the RUN position.

WARNING: Read and follow safety information at beginning of entire Sections 5 and 7
before proceeding.
1.

Install and connect unit according to Section 4.

2.

Install and connect auxiliary power equipment
cord(s) to 120 volts auxiliary power terminals according to Section 5-2.
Start engine as instructed in Section 7-6.
Place Engine Control switch in the RUN position.
Energize auxiliary equipment, if applicable. Auxiliary power may be obtained whenever engine is
running.

3.
4.
5.

7-5.

3.

AIR COMPRESSOR OPERATION (Tables 7-2
And 7-3)
Install and connect unit according to Section 4.
Install a quick-connect connector onto the air
compressor fitting in top cover of unit.
Start engine as instructed in Section 7-6.

4.

Begin operation.

1.
2.

7-6.

10.

Energize auxiliary equipment, if applicable.

11.

Wear welding helmet with proper filter lens according to ANSI Z49.1.

12.

Begin welding.

OM-166 941 Page 20

AUXILIARY POWER OPERATION

STARTING THE ENGINE

IMPORTANT: Read entire engine Owner’s Manual
(Deutz F4L-912 engine) before operating engine.
1.

Engine Prestart Checks
a. Oil Level
Check engine oil level. If oil level is low, fill to top
mark on dipstick (see engine Owner’s Manual
for oil selection specifications and Section 4-5).
If oil consumption and wetstacking occur during
run-in period, see Section 8-12.

b. Fuel Level

release ETHER STARTING AID switch after one
second.

WARNING: REMOVE FUEL CAP SLOWLY;
FUEL SPRAY may cause injury; FUEL may
be under pressure.
• Rotate fuel cap slowly and wait until hissing
stops before removing cap.

CAUTION: REENGAGING STARTER MOTOR while flywheel is rotating or EXCEEDING RATED CRANKING TIME can damage
starting components.
• Do not reengage starter motor until starter
pinion and flywheel have stopped rotating.
• Do not exceed maximum cranking time of 20
seconds.
Allow two minutes cooling time before attempting to restart engine.

Check fuel level. If necessary, fill tank with
fresh, clean fuel (see engine Owner’s Manual
for fuel specifications).
c.

Cooling System
Check the air cooling system by inspecting the
air intake and exhaust openings for blockage
and blower impeller for obstruction and free
movement. Check the blower/alternator belt for
proper tension (see the engine Owner’s Manual), and ensure that all sheet metal cowlings,
shrouds, and panels are properly in place and
secure.

3.

7-7.
1.

d. Air Cleaner

Rotate Engine Control switch to the START position, and if applicable, depress ETHER STARTING AID switch, if applicable, at the same time —

STOPPING THE ENGINE
Stop all operations, and turn off or disconnect any
auxiliary equipment.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.

Check air cleaner service indicator daily (see
Section 6-6).
2.

As soon as engine starts, release Engine Control
switch, and allow the engine to warm up for approximately three minutes with no weld or power
load applied.

2.

Rotate Engine Control switch to the OFF position.

Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters
Gauge Pressure In
Receiver (lbs.)

Orifice Diameter And Free Air Flow (CFM)
1/64”

1/32”

3/64”

1/16”

3/32”

1/8”

3/16”

1/4”

1
2
3
5
10

0.027
0.038
0.046
0.059
0.084

0.107
0.153
0.188
0.242
0.342

0.242
0.342
0.471
0.545
0.77

0.430
0.607
0.750
0.965
1.36

0.97
1.36
1.68
2.18
3.08

1.72
2.43
2.98
3.86
5.45

3.86
5.42
6.71
8.71
12.3

6.85
9.74
11.9
15.4
21.8

15
20
25
30
35

0.103
0.119
0.133
0.156
0.173

0.418
0.485
0.54
0.632
0.71

0.94
1.07
1.21
1.40
1.56

1.67
1.93
2.16
2.52
2.80

3.75
4.25
4.75
5.6
6.2

6.65
7.7
8.6
10.0
11.2

15.0
17.1
19.4
22.5
25.0

26.7
30.8
34.5
40.0
44.7

40
45
50
60
70

0.19
0.208
0.225
0.26
0.295

0.77
0.843
9.14
1.05
1.19

1.71
1.9
2.05
2.35
2.68

3.07
3.36
3.64
4.2
4.76

6.8
7.6
8.2
9.4
10.7

12.3
13.4
14.5
16.8
19.0

27.3
30.3
32.8
37.5
43.0

49.1
53.8
58.2
67.0
76.0

80
90
100
110
120

0.33
0.364
0.40
0.43
0.47

1.33
1.47
1.61
1.76
1.90

2.97
3.28
3.66
3.95
4.27

5.32
5.87
6.45
7.00
7.58

11.9
13.1
14.5
15.7
17.0

21.2
23.5
25.8
28.0
30.2

47.5
52.5
58.3
63.0
68.0

85.0
94.0
103.0
112.0
121.0

130
140
150
175
200

0.50
0.54
0.57
0.66
0.76

2.04
2.17
2.33
2.65
3.07

4.57
4.87
5.2
5.94
6.90

8.13
8.68
9.20
10.6
12.2

18.2
19.5
20.7
23.8
27.5

32.4
34.5
36.7
42.1
48.7

73.0
78.0
83.0
95.0
110.0

130.0
138.0
147.0
169.0
195.0

OM-166 941 Page 21

Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate Various Pneumatic
Equipment At Pressure Range 70-90 P.S.I.G.
MISCELLANEOUS
PORTABLE
TOOLS

Percent Use Factor And
Compressed Air Consumption (CF)

Percent Use Factor And
Compressed Air Consumption (CF)

9 sec

15 sec

21 sec

1 min

MISCELLANEOUS
PORTABLE
TOOLS

Drill, 1/18” to 3/8”

3.75

6.25

8.75

25

Burring Tool, Large

3.6

6.0

8.4

24

Drill, 3/8” to 5/16”

5.25

8.75

12.25

35

Rammers, Small

3.9

3.25

9.1

13

Screwdriver,
#2 to #6 Screw

1.8

3.0

4.2

12

Rammers, Medium

5.1

8.5

11.9

34

Screwdriver,
#6 to 5/16” Screw

3.6

6.0

8.4

24

Rammers, Large

6.0

10.0

14.0

40

Tapper, to 3/8”

3.0

5.0

7.0

20

Backfill Tamper

3.75

6.25

8.75

25

Nutsetters, to 3/8”

3.6

6.0

8.4

24

Compression Riveter

Nutsetters, to 3/4”

4.5

7.5

10.5

30

Air Motor,
1 Horsepower

3.75

6.3

8.75

25

Air Motor,
2 Horsepower

7.5

12.5

17.5

50

Air Motor,
3 Horsepower

11.25

18.75

26.3

75

Impact Wrench, 1/4”

2.25

3.75

5.3

15

Impact Wrench, 3/8”

3.0

5.0

7.0

20

Impact Wrench, 5/8”

4.5

7.5

10.5

30

Impact Wrench, 3/4”

5.25

8.75

12.25

35

Impact Wrench, 1”

6.75

11.25

15.75

45

Impact Wrench, 1-1/4”

8.25

13.75

19.2

55

Die Grinder, Small

2.25

3.75

5.3

15

Paint Spray Gun
(Production)

Die Grinder, Medium

3.6

6.0

8.4

24

HAMMERS

Horizontal Grinder, 2”

3.0

5.0

7.0

20

Horizontal Grinder, 4”

9.0

15.0

21.0

Horizontal Grinder, 6”

9.0

15.0

21.0

Horizontal Grinder, 8”

12.0

20.0

28.0

9 sec

15 sec

21 sec

1 min

0.2 cu. ft. per cycle

Air Motor Hoist
1000#

1 cu. ft. per foot of lift

Air Motor Hoist,
2000#

1 cu. ft. per foot of lift
3.0

5.00

7.00

20

Scaling Hammer

1.3

3.0

4.2

12

60

Chipping Hammer

4.5

7.5

10.5

30

60

Riveting Hammer,
Light

2.25

3.75

5.25

15

Riveting Hammer,
Heavy

4.5

7.5

10.5

30

Circular, 8”

6.75

11.25

15.75

45

Circular, 12”

9.75

16.25

23.8

65

80

Vertical Grinders and
Sanders, 5” Pad

5.25

8.75

12.25

35

Vertical Grinders and
Sanders, 7” Pad

9.0

15.0

21.0

60

SAWS

Vertical Grinders and
Sanders, 9” Pad

10.5

17.5

24.5

70

Chain, Lightweight

4.20

7.0

9.8

28

Burring Toll, Small

2.25

3.75

5.3

15

Chain, Heavy Duty

13.1

21.8

30.5

87

Always check with tool manufacturers for actual air consumption of tools being used. The above is based on averages and should not be
considered accurate for any particular make of tool.
Above tools are rated based upon typical “on-load” performance characteristics.
For other values, adjust the C.F. air consumption on a proportional basis.
The cubic feet (C.F.) air consumption for 1 minute may also be expressed as air consumption in cubic feet per minute (C.F.M.)

OM-166 941 Page 22

SECTION 8 − MAINTENANCE
8-1.
ROUTINE MAINTENANCE (Table 8-1)
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part numbers of
precautionary labels.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other material.
• Wear correct eye and body protection.
Maintenance to be performed only by qualified
persons.
A. Cables And Wiring
WARNING: Read and follow safety information at beginning of entire Section 8-1 before
proceeding.
Check interconnecting wiring and connections for
tightness and flaws. Be sure that the weld output cable
connections are clean and tight. Check the insulation for
breaks or other signs of damage. Repair or replace
cables or wiring as necessary.

C. Oil, Filter, And Drain
WARNING: Read and follow safety information at beginning of entire Section 8-1 before
proceeding.
The engine is equipped with a full-flow oil filter. Change
the oil and filter according to instructions on unit maintenance label and in engine Owner’s Manual (Deutz
F4L-912 engine). Use correct type and grade of oil as
listed in instructions for expected temperature range before next oil and filter change.
This unit is equipped with an oil drain hose secured in a
clamp behind the rear panel. A valve is provided in the
hose inside the right side base rail. To drain oil from engine, remove drain hose from clamp and open valve.
Close valve and reinstall hose into clamp before adding
new oil.
IMPORTANT: This engine is equipped with an Oil Pressure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes too
low or oil temperature rises to a level that may cause engine damage, the respective gauge/switch shuts down
the unit. The shutdown oil pressure has been factory set
at 30 psi (207 kPa), and the shutdown oil temperature
has been set at 265° F (130° C).
D. Cleaning And Inspecting
WARNING: Read and follow safety information at beginning of entire Section 8-1 before
proceeding.
When performing routine oil changes at intervals
specified on the unit maintenance label, clean and
inspect the unit as follows:
1.

Keep the inside of the welding generator clean by
blowing out the unit with clean, dry compressed
air.

2.

Wipe oil and fuel spills from engine immediately
to avoid accumulation of dust.

B. Battery
WARNING: Read and follow safety information at beginning of entire Section 8-1 before
proceeding.

3. Check for fluid leaks indicating loose oil or fuel
Inspect the battery for loose connections, damaged
connections. Tighten loose connections, and
cables, corrosion, cracked case or cover, loose
clean oil or fuel spills off engine.
holddowns, and loose or deformed terminal posts.
IMPORTANT: See the engine Owner’s Manual (Deutz
Clean and tighten connections, replace cables, or
replace battery if necessary.
F4L-912 engine) for complete engine care.
Table 8-1. Maintenance Schedule
Frequency*

Maintenance

Every day.

Check fuel and oil levels (see Sections 4-4, 4-5, and 8-1C, and engine Owner’s Manual,
Deutz F4L-912 engine).

Every 100 to 150 hours.

Change oil and filter (see engine Owner’s Manual, Deutz F4L-912 engine).
Check cables, wiring (see Section 8-1A), and battery (see Section 8-1B).
Units in heavy service environments: Check labels; clean and inspect unit (see Section 8-1).
Change fuel/water separator (see Section 8-3).

Every 250 hours.

Check and clean spark arrestor muffler (see Section 8-11).

Every 1000 hours.

Replace fuel filter (see Section 8-4).Check brushes and slip rings (see Section 8-9).
Check all labels (see IMPORTANT block, Section 8-1). Clean and inspect unit (see Section 8-1D).

*Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week.
OM-166 941 Page 23

Figure 8-1. Engine Maintenance Label

OM-166 941 Page 24
+30

°C
+40

Diesel

30 gal (113.6 L)
1-D or 2-D Cetane No. 45 min.

-10

+40
+30

+60

°F

20W-20

10W

MILLER 062 342, Fleetguard FF194, Fram P1107
Deutz 117-4423, Fleetguard FF5018, Fram P4102
MILLER 064 686
Fill filter with clean fuel before installing − read instructions on filter.

Fuel Capacity . . . . . . . . .
Fuel Grade . . . . . . . . . . .
Primary Fuel Filter/
Water Seperator . . . . . . .
Secondary Fuel Filter . . .

+20
Recommended Oil . . . . . API Service Classification CD/CE
Oil And Filter Change . . . dirty conditions . . . 100 hours or less +10
normal conditions . 125−150 hours
0
Oil Filter . . . . . . . . . . . . . . MILLER 064 677, Deutz 117-4418,
Fleetguard LF4056, Fram PH2842,
-10
Hastings P352 or FP352
-20
Oil Capacity . . . . . . . . . . . 11.5 qt (11 L) or
12 qt (11.4 L) with filter change

Check
daily.

See Engine Manual for complete engine care.
Give Engine Specification and Serial Number when ordering parts.

DEUTZ F4L912 DIESEL ENGINE

30

Optional

Do NOT
use ether.

+

Valve Clearance −Cold
Intake . . . . . 0.006 in (0.15 mm)
Exhaust . . . 0.006 in (0.15 mm)

S-146 389-B

Spark Arrestor Inspection And Service . . . . . . . . . . 250 operating hours −
see Owner’s Manual

Have only trained technician maintain injection pump and injectors. AIR, WATER, or
GASOLINE will harm the injection system. If tank is run out of fuel or fuel filter is
changed, bleeding of air is required.

Injectors . . . . . . . . . . . . . . MILLER 064 684, Deutz 223-3085
Nozzle . . . . . . . . . . . . . . . MILLER 064 685, Deutz 223-3086

Engine RPM − No Load
Weld/Power . . . . 1850

Cranking Performance at 0°F (-18°C) . . . . . . 815 Amps

Battery . . . . . . . . BCI Group 31

Avoid recirculation of air from hot air exit to blower intake.
Blower Belt . . . . . . . . . . . Deutz 223-5531, MILLER 064 690
Alternator Belt . . . . . . . . . Deutz 223-5179, MILLER 066 213
Compressor Belts (2) . . . Deutz 116-1683

Engine Cooling

Air Filter Service . . . . . . 50 hours or less − see Owner’s Manual
Air Filter Element . . . . . MILLER 020 319, AC 302C, Donaldson P10-1222,
Fleetguard AF437K, Fram CAK 253, Purolator AF-2030K

8-2.

AIR CLEANER SERVICE (Table 8-2)
CAUTION: DIRTY AIR can damage engine.
• Do not operate engine with dirty air cleaner
element in place.
• Do not operate engine without air cleaner element in place.

The air cleaner is one of the most important parts of the
engine from the standpoint of engine life. If dirty air gets
into the engine, it can cause major engine damage
within a few operating hours. The air cleaner must be
serviced when the SERVICE ENGINE AIR CLEANER
Indicator light PL1 comes on. If PL1 comes on, empty
dust cap, and inspect air cleaner and element.

The air cleaner on this unit is equipped with precleaners.
Remove the precleaner cover and empty the dust receptacle when dirt accumulates up to the indicator
marks on the side of the precleaner.
IMPORTANT: A dirty air cleaner element is usually accompanied by a loss of power and excessive smoke in
the engine exhaust.
When it becomes necessary to service the air cleaner in
the field, follow the steps in Table 8-2. Keep a spare element on hand for replacement. New elements are available from your welding equipment distributor.

Table 8-2. Air Cleaner Service

Follow
These
Easy
Steps:

1. Stop engine.
2. Wipe off cover before
opening air cleaner.

5. Wipe out element chamber
with clean, damp cloth.

7. Reinstall element.
8. Replace cover.

6. Inspect new element and all
gaskets for shipping damage before use.

3. Remove cover.
4. Remove element.
1. Don’t attempt to service air
cleaner with engine running.

Important

How To
Clean
Elements
For
Re-Use

2. Don’t blow out the inside of
the air cleaner with compressed
air.

Clean element by one of the
following methods:
Compressed Air or Washing.
Compressed air is recommended
when element will be re-used
immediately because a washed
element must be dried before

3. Don’t leave open air cleaner exposed
to blowing dust while you clean element.
Replace cover.
4. If air cleaner is horizontally mounted,
be sure that dust cup is positioned so
arrows point up.
re-use. However, washing does
a better job and must be used when
exhaust soot has lodged in fine pores
of the filter media. Use Donaldson D-1400
detergent which contains a special
additive for removing soot and carbon.

5. For Donaclone air cleaners ,
don’t blow out Donaclone tube
section without element, cover
and inner cover (if any)
correctly installed or you will
blow dust into the engine.

(When cleaning Cyclopac
elements, do not remove
plastic fin assembly − backflowing with compressed air or
washing will remove dust from
beneath the fin assembly).

Replace element after 6 cleanings or
annually, whichever occurs first.

Compressed Air

Washing

Inspection

Direct air through element in
the direction opposite to normal
air flow through the element.
Move nozzle up and down while
rotating element. Keep nozzle
at least one inch from pleated
paper. Maximum air pressure −
100 P.S.I.

1. Soak element 15 minutes or more
in Donaldson D-1400 and water solution.
See carton for full instructions.

Place bright light inside
element and rotate element
slowly. If any rupture, holes
or damaged gaskets are
discovered − replace.

2. Rinse until water is clear (Maximum
water pressure 40 P.S.I.)
3. Air-dry or use warm flowing air, max.
160 F. Do not use compressed air or
light bulbs.

S-0091/4-89

OM-166 941 Page 25

8-3.

Oil Fill Cap

FUEL/WATER SEPARATOR AND SLUDGE
DRAIN PLUG
WARNING: ENGINE FUEL can cause fire or
explosion.
• Do not drain fuel tank while engine is running.

•
•
•
•

Fuel Filter

Do not smoke while handling fuel.
Do not allow fuel to drain onto the engine or
other components.
Do not spill fuel; if spilled, wipe up.

Engine Speed
Adjustment
Screw

Have a fire extinguisher nearby, and know
how to use it.

A. Fuel/Water Separator
The fuel/water separator, located on the right base rail
near the engine, is provided to drain off water from the
fuel system. Before starting the engine for the first time
each day, open the fuel drain plug on the bottom of the
separator, and drain the water into a metal container.
Close the drain plug at the first signs of fuel. The fuel/
water separator should be changed every 125 hours of
operation or every four months, whichever occurs first.

Ref. ST-147 321-A

Figure 8-2. Right Side And Rear View Of Engine
8-5.

B. Sludge Drain Plug

WARNING: SPARKS OR FLAMES can cause
BATTERY GASES to explode; BATTERY
ACID can burn eyes and skin.
• Stop engine before disconnecting or
connecting battery cables.
• Keep sparks, flames, cigarettes, and other
ignition sources away from batteries.
• Do not allow tools to cause sparks when
working on a battery.
• Always wear a face shield and proper
protective gloves and clothing when working
on a battery.

A sludge drain plug, located on the lower right front corner of the unit, is provided to drain off sediment from the
fuel tank. Once a week, drain the sludge into a metal
container. If the fuel is extremely dirty, drain the sludge
daily.

8-4.

FUEL FILTER (Figure 8-2)
WARNING: ENGINE FUEL can cause fire or
explosion.
• Stop engine before working on fuel system.

•
•
•
•
•

Do not spill fuel; if spilled wipe up.
Do not service fuel filter if engine is hot or running.
Do not service fuel filter near sparks or open
flame.
Do not smoke while servicing fuel filter.
Have a fire extinguisher nearby, and know
how to use it.

This welding generator is equipped with a cartridge-type
fuel filter located above the oil filter on the right side of
the unit. The fuel filter should be replaced after 1000
hours of operation, or more often depending on the quality of fuel used and how dusty and dirty the location is in
which the engine is being used. To replace the fuel filter,
refer to the Engine Manufacturer’s Manual.

OM-166 941 Page 26

BATTERY REPLACEMENT PROCEDURE

Use the following procedure to prevent sparks when
removing or installing a battery:
1.

Be sure engine is fully stopped, and Engine
Control switch is in the OFF position.

2.

Locate battery in unit.

3.

Open door or remove panels as necessary.

4.

Disconnect negative (−) battery cable first and
positive (+) cable last.

5.

Remove holddown device.

6.

Remove battery.

7.

Install new (or charged) battery.

8.

Reinstall and secure holddown device.

9.

Connect positive (+) cable first and negative (−)
cable last.

10.

Securely reinstall or close doors or panels.

8-6.

MAINTENANCE-FREE BATTERY CHARGING
WARNING: CHARGING A FROZEN BATTERY can cause the battery to explode and
result in serious personal injury or damage
to equipment.
• Allow battery to warm up to 60° F (16°C) before charging if battery is frozen.
BATTERY ACID can burn eyes and skin and
destroy clothing and other materials; BATTERY GASES can explode and shatter battery.
• Wear a face shield, proper protective clothing, and remove all metal jewelry.
• Do not spill or splash battery fluid.
• Do not apply pressure to walls of filled battery—use battery carrier or place hands on
opposite corners when lifting battery.
• Keep sparks, flames, cigarettes, and other ignition sources away from batteries.
• Use enough ventilation to keep battery gases
from building up during and for several hours
after battery charging.
• Do not touch or move connections on battery
while battery charger is on.
• Turn battery charger off before making connections to battery.
• Do not lean over battery when charging.
• Be sure battery charger connections to battery are clean and tight.
• Keep vent caps in place and cover top of battery with damp cloth.
• Be sure battery charger output matches battery voltage.
• Turn the battery charger off before disconnecting the charger from the battery.

1.

Remove battery from unit, and place on a level
worktable or other suitable surface.

2.

If battery has removable vent caps, check the
condition of the electrolyte as follows:
a. Check electrolyte temperature in one of the
center cells with a battery thermometer. For
each 10°F (6°C) increment above 80°F (27°C),
a correction factor of 0.004 specific gravity
must be added to the specific gravity reading
taken in Step 2b. For each 10°F (6°C) increment below 80°F (27°C), 0.004 must be subtracted from the reading taken in Step 2b.
b. Check the specific gravity of each cell with a hydrometer. (Draw in and expel the electrolyte two
or three times from the first cell to be tested to
adjust the temperature of the hydrometer to
that of the electrolyte.)
c.

If a corrected specific gravity reading of 1.225 at
80°F (27°C) is not obtained, replace the vent
caps and recharge the battery following the battery charger manufacturer’s instructions.

3.

If the battery does not have removable vent caps,
check the condition of the battery as follows:
a. Check the stabilized open−circuit voltage of the
battery. For a 12 volt battery, any reading below
12.4 volts indicates the battery needs charging.
Disconnect both battery cables from the battery, and allow battery voltage to stabilize for
several hours.
b. If the stabilized open−circuit voltage is below
12.4 volts, charge the battery following the battery charger manufacturer’s instructions.

4.

Remove damp cloth from battery.

5.

Reinstall battery in unit.

6.

Replace battery holddown, and tighten securely.
Do not overtighten.

7.

Connect positive (+) battery cable to positive (+)
battery terminal.

8.

Connect negative (−) battery cable to negative
(−) battery terminal.

8-7.

GOVERNOR

The governor has been set at the factory and should not
require further adjustment.
8-8.

ENGINE SPEED ADJUSTMENTS (Figure 8-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed only by qualified
persons.

The engine speeds have been factory adjusted and
should not require frequent readjustment. After tuning
the engine, check the speeds with a tachometer. With
no load applied, the weld/power speed should be 1860
rpm. If necessary, adjust the speeds as follows:
1.

Open and secure right rear side door.

2.

Loosen nut on end of engine speed adjusting
screw (see Figure 8-2).

3.

Start the engine as instructed in Section 7-6.

4.

Adjust the weld/power speed as follows:

IMPORTANT: All directions, such as clockwise and
counterclockwise, are with respect to the operator facing the rear panel of the unit.
a. To increase weld/power speed, rotate the engine speed adjustment screw clockwise.
b. To decrease weld/power speed, rotate the engine adjustment screw counterclockwise.
OM-166 941 Page 27

5.

When the weld/power speed reaches 1860 rpm,
prevent the adjustment screw from turning, and
tighten the securing nut.

6.

Stop engine.

7.

Close and secure side door.

8-9.

No indicator is provided to show the amount of ether left
in the cylinder; therefore, it is recommended that a spare
cylinder be kept on hand. Generally, the ether cylinder is
empty if the engine fails to start in cold weather while utilizing the cold weather starting system.
WARNING: IMPROPER HANDLING OR EXPOSURE TO ETHER can seriously harm
your health.
• Follow the manufacturer’s safety instructions
on the cylinder when handling ether components.

BRUSHES AND SLIP RINGS (Figure 8-3)
WARNING: ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−) battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.

Brush life is very good under most operating conditions.
The brushes and slip rings should be inspected every
six months or whenever excitation voltage is lost. Be
sure that slip rings are clean and brushes are free to
move. If the welding generator has been operating under extremely dusty or dirty conditions, increase the frequency of inspection.
Under normal use, the slip rings will discolor to a dark
brown. If a buildup of brush material is noted, it may be
necessary to clean the slip rings. Clean rings with a
number 220 or finer sandpaper, and polish rings with
crocus cloth. Never use emery cloth because part of the
emery will embed itself into the rings and, in turn, destroy the carbon brushes.
Replace the brushes if they become chipped or broken
or if less than 1/2 in. (12.7 mm) of brush material is left.
1/2 in. (12.7 mm)
Minimum

S-0234

Figure 8-3. Brush Replacement

The cylinder can be weighed to determine the amount
of ether inside. The cylinder weighs 33 ounces (936 gr)
when full, and it weighs 15 ounces (425 gr) when empty.
To replace the ether cylinder, see Section 4-10.
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these areas, the system may not work.
IMPORTANT: After installing or replacing ether cylinder, do not use or test ether start system for at least 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
8-11.

SPARK ARRESTOR
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine and disconnect negative (−)
battery cable from battery before beginning
this installation.
MOVING PARTS can cause severe injury.
• Keep away from moving parts such as fans,
belts, and rotors.
ENGINE EXHAUST SPARKS can cause fire.
• Exhaust spark arrestor must be installed in
accordance with local, state, and federal
regulations.
• Stop engine before cleaning spark arrestor.
• Clean spark arrestor in a noncombustible
environment.
HOT PARTS can cause severe burns.
• The exhaust system must be cold when
servicing the spark arrestor.

8-10. ETHER STARTING AID (Optional)
CAUTION:
ETHER INJECTION WHILE
ENGINE IS RUNNING can cause engine
damage.
• Do not actuate ETHER STARTING AID while
engine is running.
The ether used in the cold weather starting aid system is
contained in a replaceable cylinder located behind the
right rear side door on the center portion of the frame.
OM-166 941 Page 28

Internal combustion engines operating in a highly combustible environment are a common fire hazard. Glowing carbon particles blown out with the exhaust can retain sufficient heat to ignite materials. While no practical
spark arresting device will stop all sparks, this device will
minimize fire hazards by removing and trapping most
solid particles provided that is is properly maintained.
Inspect and service spark arrestor every 250 operation
hours.

Removal of the device from the exhaust system is not
necessary for servicing. Proceed as follows to service
spark arrestor:
1.

Stop the engine, and allow the exhaust system to
cool.

2.

Remove the cleanout plug from the bottom of the
spark arrestor. If a crust has formed over the
hole, break it loose with a screwdriver or similar
tool.

3.

Start the engine, and run it at idle rpm to blow collected particles out the cleanout hole. If particles
are slow to discharge, momentarily cover the end
of the exhaust stack.

4.

Stop the engine, and allow the exhaust system to
cool.

5.

Replace and secure the cleanout plug.

occur during the run-in period if the engine is left at idle
rpm too long, or the welding generator is not heavily
loaded.
If wetstacking occurs, complete one of the following procedures to dry the engine (see engine Owner’s Manual,
F4L-912 diesel engine). A resistance load is required to
fully load the generator during the run-in procedure. A
load bank or resistance grid may provide a constant load
for run-in, however, a load bank is preferred. If a load
bank is available, proceed with the run-in procedure provided in Subsection A. If a resistance grid is being used,
proceed to Subsection B.
A. Run-In Procedure Using Load Bank (Diagram
8-1)
WARNING: Read and follow safety information at beginning of entire Section 8-12
before proceeding.
1.

8-12. RUN-IN PROCEDURE
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Stop engine before inspecting, connecting,
or servicing.
• Do not leave live unit unattended when
engine is running.
• Keep all panels, covers, and guards
securely in place while engine is running.
MOVING PARTS can cause severe injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on hot engine parts or components.
CAUTION: LOW OIL LEVEL can damage
engine; ENGINE MAY USE OIL AND WETSTACKING may occur during run-in period.
• Check oil level several times a day during
run-in period, and add oil if required.
• See engine Owner’s Manual (Deutz
F4L-912 diesel engine) for run-in information.
• Do not idle engine longer than necessary
during run-in period.
• Piston rings seat faster if engine runs at
weld/power rpm, and the welding generator
is kept loaded during the run-in period.
The run-in procedure for diesel engines is different than
those associated with gasoline engines. Diesel engines
must be run at near-rated load during the run-in period to
ensure proper seating of piston rings and to prevent
wetstacking. Wetstacking is an accumulation of unburned fuel and oil in the exhaust pipe. Wetstacking can

Stop engine.

IMPORTANT: Weld cables supplied with load bank may
be inadequate for run-in procedure. Use weld cables of
proper size with appropriate connectors to connect load
bank to generator (see load bank Owner’s Manual).
2.

Connect cables from load bank to generator weld
output terminals observing correct polarity (see
Diagram 8-1).

3.

Place all load switches in the OFF position.

IMPORTANT: If load bank requires 115 volts ac, it may
be connected to the welding generator auxiliary power
terminal strip, if applicable.
4.

Place welding generator AMPERAGE & VOLTAGE ADJUSTMENT control in the minimum position.

5.

Start engine as instructed in Section 7-6, and allow engine to warm up for approximately three
minutes.

6.

Adjust load bank switches and generator controls
to provide a load equal to rated generator output.
For example, if rated generator output is 350 amperes, 40 volts at 100% duty cycle, adjust
switches until values indicated by load meters
equal rated generator output.

7.

Allow engine to run under load for at least one
hour. Check engine and load bank meters after
the first five minutes and every 15 minutes thereafter to be sure equipment is operating properly.

8.

After running engine under load for at least one
hour, remove load by shutting down load bank.

9.

Allow engine to idle for approximately three minutes to permit internal engine temperatures to
equalize.
OM-166 941 Page 29

Welding
Generator
Load Bank

Positive (+)
Weld Output
Terminal

+

−

Negative (−)
Weld Output
Terminal

−

+

Voltmeter
And
Ammeter

Weld
Cables

S-0456

Diagram 8-1. Load Bank Connections

10.

Stop engine, and disconnect load bank cables.

11.

Allow exhaust system to cool.

12.

Inspect inside of exhaust pipe. If pipe is dry, the
run-in procedure is complete. If pipe is coated
with a wet, black, tar-like substance, repeat runin procedure.

are not provided, connect voltmeter and clampon dc ammeter as shown in Diagram 8-2.
9.

Connect remaining ends of weld cables to generator weld output terminals (polarity is not important).

10.

Start engine as instructed in Section 7-6, and allow engine to warm up for approximately three
minutes.

B. Run-In Procedure Using Resistance Grid (Diagram 8-2)

CAUTION: ARCING can damage switch
contacts.
• Do not change the position of the grid
switches while engine is running.

WARNING: Read and follow safety information at beginning of entire Section 8-12
before proceeding.
1.

Stop engine.

2.

Obtain resistance grid adequately sized for rated
output of welding generator.

3.

Obtain two weld cables of proper size to connect
resistance grid to generator (see Section 4-7).

4.

If a voltmeter and ammeter are not provided on
the welding generator, obtain a voltmeter and
clamp-on dc ammeter.

5.

Place welding generator AMPERAGE & VOLTAGE ADJUSTMENT control in the minimum position.

6.

Adjust grid switches and generator controls to
provide a load approximately equal to rated generator output.
For example, if rated generator output is 350 amperes, 40 volts at 100% duty cycle, adjust
switches until values indicated by meters equals
rated generator output.

7.

8.

Connect one weld cable to grid input receptacle
and remaining weld cable to grid output receptacle (see Diagram 8-2).
If a voltmeter and ammeter are provided on the
welding generator, proceed to Step 9. If meters

OM-166 941 Page 30

Arcing causes the contacts to become pitted
and eventually inoperative.
11.

Check meters. Adjust load with generator controls or, if necessary, by changing positions of grid
switches until values indicated by meters equal
rated generator output.

12.

Allow engine to run under load for at least one
hour. Check engine and meters after the first five
minutes and every 15 minutes thereafter to be
sure equipment is operating properly

13.

After running engine under load for at least one
hour, remove load by shutting down resistance
grid.

14.

Allow engine to idle for approximately three minutes to permit internal engine temperatures to
equalize.

15.

Stop engine, and disconnect weld cables.

16.

Allow exhaust system to cool.

17.

Inspect inside of exhaust pipe. If pipe is dry, the
run-in procedure is complete. If pipe is coated
with a wet, black, tar-like substance, repeat runin procedure.

Welding
Generator
Voltmeter And
Ammeter
(If so equipped)

Resistance Grid

Input And Output
Receptacles
Weld Output
Terminals
(Polarity Not
Important)
Weld
Cables

♦

Clamp-On
DC Ammeter

V

♦ Voltmeter

A

♦ Required if welding generator is not equipped with meters.
S-0457

Diagram 8-2. Resistance Grid Connections

SECTION 9 − TROUBLESHOOTING
9-1.

•

GENERAL

It is assumed that proper installation has been made,
according to Section 4 of this manual, the operator is familiar with the function of controls, the welding generator
was functioning properly, and the trouble is not related to
the welding process.
9-2.

•
•
•

BOOSTER BATTERY JUMP STARTING

If it is necessary to jump start this unit, use the following
safety precautions and the step-by-step procedures in
order of appearance.

•

WARNING: BATTERY GASES OR A DAMAGED BATTERY can explode thereby shattering the battery; BATTERY ACID can burn
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND IMPROPER CONNECTIONS can cause serious
personal injury and damage equipment.
• Keep sparks, flames, cigarettes, and other ignition sources away from battery.

•

•
•
•
•

Ensure that all personnel are a safe distance
from batteries and clear of moving parts while
starting.

•

•

Keep jumper cables clear of moving parts.
Ensure that both batteries are of the same
voltage.
Do not jump start a trailer mounted welding
generator with the towing vehicle battery unless the trailer is completely disconnected
from the towing vehicle.
Do not jump start a vehicle mounted welding
generator from the vehicle battery.
If booster battery is installed in vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
Do not jump start by applying power to weld
output receptacles or terminals.
Do not allow jumper cables to contact any
other metal while attaching or removing cables.

1.

Use properly insulated jumper cables of adequate size.

2.

Connect ends of one cable to positive (+) terminals of each battery.
Connect one end of other cable to negative (−)
terminal of booster battery.
Connect remaining end of cable to welding generator engine block at least 18 inches (457 mm)
from battery (do not connect to welding generator
case, frame, or equipment grounding terminal as
damage to equipment can result).

Do not jump start a frozen or completely discharged battery.

3.

Do not jump start a battery which has loose
terminals or one having evidence of damage
such as a cracked case or cover.

4.

Be sure that vent caps are tight and level on
both batteries and cover both batteries with a
damp cloth.

Wear correct eye and body protection, and
remove all metal jewelry.

5.

Wait at least one minute after connecting cables
before starting engine.
OM-166 941 Page 31

6.

Start engine following procedures outlined in
Section 7 (Sequence of Operation) of this manual. If the unit does not start after cranking for
twenty seconds, stop the jump starting procedure. More than twenty seconds seldom starts
the engine unless some mechanical adjustment
is made.

If CB3 opens, 115 volts ac output to socket/terminal D of
REMOTE 9 receptacle RC3 and terminal strip 3T stops,
and the remote amperage/voltage control will not
function.
C. Replacement Of Low Oil Pressure/High Oil
Temperature Shutdown System Fuse F

7.

Remove jumper cable from engine block.

8.

Remove other end of same cable from booster
battery negative (−) terminal.

9.

Remove other jumper cable from booster battery
positive (+) terminal.

1.

10.

Remove remaining end of cable from welding
generator battery positive (+) terminal.

Remove securing screws, and open upper front
access door.

2.

11.

Discard damp cloths.

Locate shutdown switch MS1 on left, rear side of
front access door.

3.

Locate fuse F on bottom of shutdown switch
MS1.

WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.

4.

Remove and check fuse, and replace if necessary.

Stop engine, and disconnect negative (−) battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious personal
injury.
• Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
INCORRECT FUSE can damage unit.
• Be sure replacement fuse is same size, type,
and rating.

5.

Close and secure front access door.

9-3.

OVERLOAD PROTECTION (Figure 4-2)

•

A. Circuit Breaker CB1 (Figure 4-2)
WARNING: Read and follow safety information at beginning of Section 9-3 before proceeding.
Circuit breaker CB1 protects the 120 volts ac auxiliary
power terminals on terminal strip 3T from overload. CB1
is located behind the lower front door. When CB1 opens,
the ON/OFF switch goes to the OFF position, and 3T will
not operate. If CB1 opens, locate and correct the problem, and place the circuit breaker switch in the ON position.

WARNING: Read and follow safety information at beginning of Section 9-3 before proceeding.

9-4.

CIRCUIT
TIONS

BOARD

HANDLING

PRECAU-

WARNING: ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−) battery cable from battery before inspecting,
maintaining, or servicing.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit board components.

•
•
•

Put on properly grounded wrist strap BEFORE handling circuit boards.
Transport all static−sensitive components in
proper static-shielding carriers or packages.
Perform work only at a static−safe work area.

INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
• Be sure that plugs are properly installed and
aligned before closing access door.

WARNING: Read and follow safety information at beginning of Section 9-3 before proceeding.

EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle movement when disconnecting or connecting
board plugs and removing or installing board.

Circuit breaker CB3 protects the unit wiring from overload and damage. CB3 is located behind the lower front
door.

If any circuit board is not working, follow the precautions
above, and contact the nearest Factory Authorized Service Station/Service Distributor.

B. Circuit Breaker CB3 (Figure 4-2)

OM-166 941 Page 32

9-5.

The following tables are designed to diagnose and provide remedies for some of the troubles that may develop
in this welding generator.

TROUBLESHOOTING (Tables 9-1 Thru 9-4)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.

•

Use these tables in conjunction with the circuit diagram
while performing troubleshooting procedure. If the
trouble is not remedied after performing these procedures, contact the nearest Factory Authorized Service
Station/Service Distributor. In all cases of equipment
malfunction, strictly follow the manufacturer’s procedures and instructions.

Stop engine, and disconnect the negative (−)
battery cable before inspecting, maintaining,
or servicing.

MOVING PARTS can cause serious injury.
• Keep away from moving parts such as fans,
and rotors.
HOT ENGINE PARTS can cause severe
burns.
• Wear protective gloves and clothing when
working on a hot engine.
Troubleshooting to be performed only by qualified persons.

Table 9-1. Weld/Power Troubleshooting

TROUBLE
No weld output.

PROBABLE CAUSE

REMEDY

Amperage Ranges switch S9 Place S9 in LOW OUTPUT or HIGH OUTPUT
between positions.
position (see Section 6-1).
OUTPUT
(CONTACTOR) Place S5 in ON position, or install Remote Conswitch S5 in REMOTE position tactor Control device.
and Remote Contactor device
not connected.
Incorrect or poor connection to Check and secure connections (see Section
REMOTE 9 receptacle or termi- 4-8).
nal strip 3T.
Circuit breaker
(GMAW only).

CB3

open Reset CB3 (see Section 9-3).

Poor contact between slip rings Clean slip rings (see Section 8-9).
and brushes.
Replace brushes according to Section 8-9.
Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
Erratic weld output.

Loose or dirty connections.

Check connections both inside and outside the
unit.

Connection at work.

Check connection. Be sure connection is clean
and tight.

Damp electrode.

Use dry, properly stored electrode.

Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
High welding output voltage.

Electrode polarity.

See Section 4-7C.

High engine speed.

Check and adjust engine speed according to
Section 8-8.

Field Current Regulator board See Section 9-4, and contact nearest Factory
PC1.
Authorized Service Station/Service Distributor.
Wire feeder inoperative.

Circuit breaker CB3.

Reset CB3 according to Section 9-3.
OM-166 941 Page 33

Table 9-2. Auxiliary Power Troubleshooting
AUXILIARY POWER
TROUBLE

PROBABLE CAUSE

No 120 volt output at 3T termi- Circuit breaker CB1 open.
nals L and M.
Poor contact between slip
rings and brushes.

REMEDY
Reset CB1 (see Section 9-3).
Clean slip rings (see Section 8-9).
Replace brushes according to Section 8-9.

High auxiliary power output
voltage.

High engine speed.

Check and adjust engine speed according to
Section 8-8. (Maximum voltages should not
exceed 132 volts for single-phase power.)

Table 9-3. Engine Troubleshooting
TROUBLE
Engine does not start.

PROBABLE CAUSE

REMEDY

Out of fuel.

Fill fuel tank, and air vent fuel system (see Engine Manufacturer’s Manual.)

Battery problem.

Check engine battery charging system according to engine service manual (not supplied with
engine).
Inspect electrical system (see Section 8-1). If
trouble is isolated to battery, replace it.
Jump start the engine using approved safety
practices and booster battery (see Section
9-2).

Engine suddenly shuts down.

Engine Control switch S1.

Check S1, and replace if necessary.

Oil Pressure gauge/switch or
Oil Temperature gauge/switch
activated, or other engine
trouble.

See Sections 6-10 thru 6-11; see Engine Manufacturer’s Manual (F4L-912 engine).

MS1 fuse F.

Check and replace F, if necessary (see Section 9-3).

Broken cooling belt.

Check and replace belt (see Section 6-15).

High oil temperature.

Check engine oil level and add oil if necessary;
check for cooling air flow obstructions.

Low oil pressure.

Check engine oil level, and add oil if necessary
(see Section 4-5).

MS1 fuse F.

Check and replace F if necessary (see Section
9-3).

Table 9-4. Air Compressor Troubleshooting
AIR COMPRESSOR
TROUBLE

CAUSE

REMEDY

Air compressor fails to build
pressure or builds pressure
slowly.

Engine air compressor.

Service air compressor. Contact nearest Authorized Service Station/Service Distributor.

Pneumatic tools freeze up.

Moisture in compressed air.

Induce an antifreeze solution into the air supply. Contact nearest Authorized Service Station/Service Distributor.

OM-166 941 Page 34

NOTES

OM-166 941 Page 35

SECTION 10 − ELECTRICAL DIAGRAMS

Diagram 10-1. Circuit Diagram For Welding Generator
OM-166 941 Page 36

SC-168 908-B

OM-166 941 Page 37

OM-166 941 Page 38

Figure 11-1A. Main Assembly

74

76

73

75

Fig
11-2

1

2

72

3

77

79

5

71

70

78

4

17

6

69

7

7

68

63

8

61

65

62

64

9

10

11

12

59

14

67

66

15

58 57

16

Fig 11-3

Fig 11-4

60

13

50

56

17

47

48

49

51

1

52

53

54

55

15

46

18

42

19

45
36

20

37

44

4 21

43

22

42

23

41

24

40

1

25

26

39

34

35

32

36 37

33

27

38

31

30

29

28

SECTION 11 − PARTS LIST

ST-800 491-B (1 of 2)

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-1A. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...

1
2
3
4
5
6
7
8
9
10
11
12
13

. . . . . . . . . . . . . . . . . . . 134 834
. . . . . . . . . . . . . . . . . . . 131 123
. . . . . . . . . . . . . . . . . . . 146 240
. . . . . . . . . . . . 1063920009309
. . . . . . . . . . . . 0302390009309
. . . . . . . . . . . . 1261610009309
. . . . . . . . . . . . 1448660009309
. . . . . . . . . . . . 1448670009309
. . . . . . . . . . . . 1448320009309
. . . . . . . . . . . . . . . . . . . 602 904
. . . . . . . . . . . . . . . . . . . 010 917
. . . . . . . . . . . . 1224390009309
. . . . . . . . . . . . . . . . . . . 138 098

. . . 14 . . . Shunt . . . . . . . . . 072 426
. . . 15 . . . . . . . . . . . . . . . . . . . 025 248
. . . 16 . . . . . . . . . . . 14172390009309
. . . 17 . . PLG7,12 . . . . . . . . 047 636
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535
. . . 18 . . . . . . . . . . . . . . . . . . . 143 922
. . . 19 . . . . T2 . . . . 1479850009309
. . . . . . . . . . RC8 . . . . . . . . . . 167 640
. . . . . . . . . . . . . . . . . . . . . . . . . 113 633
. . . . . . . . . PLG8 . . . . . . . . . 136 810
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066
. . . 20 . . . . Z1 . . . . 1290740009880
. . . 21 . . . . . . . . . . . . 1107430009309
. . . 22 . . . . . . . . . . . . 1551670009309
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965
. . . 23 . . . . . . . . . . . . . . . . . . . 017 479
. . . 24 . . . . . . . . . . . . 1551680009309
. . . 25 . . . . . . . . . . . . . . . . . . . 108 081
. . . 26 . . . . . . . . . . . . . . . . . . . 134 456
. . . 27 . . . . . . . . . . . . 1186440009309
. . . 28 . . . . . . . . . . . . . . . . . . . 032 452
. . . 29 . . . . BAT . . . . . . . . . . 012 724
. . . . . . . . . . . . . . . . . . 1448270009309
. . . 30 . . . . . . . . . . . . . . . . . . . 010 460
. . . 31 . . . CR2,4 . . . . . . . . . 090 104
. . . . . . . . PLG9,10 . . . . . . . . 148 850
. . . 32 . . . . . . . . . . . . . . . . . . . 601 851
. . . 33 . . . . . . . . . . . . 1169780009309
. . . 34 . . . . . . . . . . . . . . . . . . . 083 553
. . . 35 . . . . . . . . . . . . . . . . . . . 145 281
. . . 36 . . . . . . . . . . . . . . . . . . . 099 542
. . . 37 . . . . . . . . . . . . . . . . . . . 134 836
. . . . . . . . . . . . . . . . . . . . . . . . . 023 562
. . . 38 . . . . . . . . . . . . . . . . . . . 117 227
. . . 39 . . . . . . . . . . . . . . . . . . *062 342
. . . 40 . . . . . . . . . . . . . . . . . . . 089 120
. . . 41 . . . . . . . . . . . . . . . . . . . 073 433
. . . 42 . . . . . . . . . . . . 1194860009309
. . . 43 . . . . 2T . . . . . . . . . . . 163 656
. . . 44 . . . . . . . . . . . . 0570560009309
. . . 45 . . . . . . . . . . . . . . . . . . . 081 646
. . . 46 . . . . . . . . . . . . . . . . . . . 146 357
. . . 47 . . . . . . . . . . . . . . . . . . . 121 823
. . . 48 . . . . . . . . . . . . . . . . . . . 010 678

..
..
..
..
..
..
..
..
..
..
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HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . .
SHIELD, heat upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, air 43.000 3/4 swivel both ends . . . . . . . . . . . . . . . . . . . . . . .
FITTING, stl flrd conn fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . .
FITTING, pipe brs adapter 1/2NPT x M22 x 1.5 . . . . . . . . . . . . . . . .
SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, control air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe brs adapter 1/2fem NPT x M22 x 1.5 . . . . . . . . . . . .
FITTING, pipe stl elb st .500NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HANGER, minerallic No. 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 5 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHUNT, meter 50MV 1000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insul .250-20 x 1.250 lg . . . . . . . . . . . . . . . . . . . . . . . . .
. . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . .
. . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3 . . . . . . . .
. . TRANSFORMER, control (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . CONNECTOR, rect pin 20-14ga Amp 350218-1 . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . .
. . REACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, stl flrd conn M 1/2tbg x .750-16 . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . .
. . CABLE, bat neg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOLD DOWN, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, bat pos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BATTERY, stor 12V 550crk 165RSV . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR ASSEMBLY, battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, stl .312-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 12VDC SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SOCKET, relay 5 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, stl slf lkg hex reg .625-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BASE, filter fuel w/adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, hose brs barb elb M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . .
. . CLAMP, hose .645-.828clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, SAE .375 ID x .620 OD (order by ft) . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose .312-.875clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SEPARATOR, fuel filter & water . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose .375-.450clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . .
. . TUBE, pick-up fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 65A 12P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg term strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, brs barbed M 3/8tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . . . .
. . SENDER, fuel gauge 11.000 deep . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning do not lift from this end . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, pipe brs elb st 1/4NPT LH . . . . . . . . . . . . . . . . . . . . . . . . .

4ft
1
2
1
1
1
2
1
1
1
3
1
1
1
3
1
2
14
2
1
1
4
1
4
1
1
1
2
2
1
2
1
1
1
1
1
1
2
2
4
1
1
2
3
7ft
2
1
1
1
2
2
1
1
1
1
1
1

OM-166 941 Page 39

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-1A. Main Assembly (Continued)
. . . 49 . . . . . . . . . . . . . . . . . . . 073 433
. . . 50 . . . . . . . . . . . . 0456660009309
. . . 51 . . . . . . . . . . . . 1187900009309
. . . 52 . . . . . . . . . . . . . . . . . . . 010 914
. . . 53 . . . . . . . . . . . . . . . . . . . 087 341
. . . 54 . . . . . . . . . . . . 1551660009309
. . . . . . . . . . . . . . . . . . . . . . . . . 121 699
. . . . . . . . . . . . . . . . . . . . . . . . . 601 965
. . . . . . . . . . . . . . . . . . . . . . . . . 602 213
. . . . . . . . . . . . . . . . . . . . . . . . . 601 871
. . . 55 . . . . . . . . . . . . 1311880009309
. . . . . . . . . . . . . . . . . . . . . . . . . 007 025
. . . . . . . . . . . . . . . . . . . . . . . . . 602 218
. . . . . . . . . . . . . . . . . . . . . . . . . 085 980
. . . 56 . . . . . . . . . . . . 1311270009309
. . . 57 . . . . SR3 . . . . . . . . . . 142 507
. . . . . . . . . . . . . . . . . . 1448180009309
. . . 58 . . . . . . . . . . . . . . . . . . . 030 170
. . . 59 . . . RC12 . . . . . . . . . 047 637
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534
. . . 60 . . . . . . . . . . . . 1215410009309
. . . 61 . . . . . . . . . . . . . . . . . . . 026 947
. . . 62 . . . . . . . . . . . . 1376100009309
. . . 63 . . . . . . . . . . . . . . . . . . . 079 739
. . . 64 . . . PLG6 . . . . . . . . . 048 598
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534
. . . 65 . . . . . . . . . . . . . . . . . . . Fig 11-4
. . . 66 . . . . . . . . . . . . . . . . . . . Fig 11-3
. . . 67 . . . . . . . . . . . . . . . . . . . 122 354
. . . 68 . . . . . . . . . . . . . . . . . . . 107 343
. . . 69 . . . . . . . . . . . . 0240350009309
. . . 70 . . . . . . . . . . . . 1448230010202
. . . 71 . . . . . . . . . . . . . . . . . . . 147 911
. . . 72 . . . . . . . . . . . . . . . . . . . 134 792
. . . 73 . . . . . . . . . . . . 1448210009309
. . . . . . . . . . . . . . . . . . 1448220009309
. . . 74 . . . . . . . . . . . +1292260010202
. . . 75 . . . . . . . . . . . . . . . . . . . Fig 11-2
. . . 76 . . . . . . . . . . . . . . . . . . . 131 125
. . . 77 . . . . . . . . . . . . . . . . . . . 131 124
. . . 78 . . . . . . . . . . . . 1312430009309
. . . 79 . . . . . . . . . . . . 1317500009309
. . . . . . . . . . . . . . . . . . . . . . . . . 120 188
. . . . . . . . . . . . . . . . . . . . . . . . . 136 615
. . . . . . . . . . . . . . . . . . . . . . . . . 164 617
. . . . . . . . . . . . . . . . . . . . . . . . . 164 616
. . . . . . . . . . . . . . . . . . . . . . . . . 135 784
. . . . . . . . . . . . . . . . . . . . . . . . . 149 616
. . . . . . . . . . . . . . . . . . . . . . . . . 010 021
. . . . . . . . . . . . . . . . . . . . . . . . . 034 116
. . . . . . . . . . . . . . . . . . . . . . . . . 010 014
. . . . . . . . . . . . . . . . . . . . . . . . . 020 279
. . . . . . . . . . . . . . . . . . . . . . . . . 127 854
. . . . . . . . . . . . . . . . . . . . . . . . . 089 256
. . . . . . . . . . . . . . . . . . . . . . . . . 010 143

. . FITTING, brs barbed M 3/16tbg x 1/4NPT . . . . . . . . . . . . . . . . . . . .
. . LATCH, door snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ANGLE, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HANGER, minerallic No. 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUMPER, door 1.000 OD x .750 high . . . . . . . . . . . . . . . . . . . . . . . .
. . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .375-16 x 1.000hexhd (used on fuel filter bracket also) .
. . WASHER, lock stl split .375 (used on fuel filter bracket also) . . . . .
. . NUT, stl hex jam .375-16 (used on fuel filter bracket also) . . . . . . .
. . FRAME, mtg reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .625-11 x 1.250 . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, lock stl split .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, stl hex full fnsh .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, rect RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER, si 3ph 450A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, rectifier AC to AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . .
. . BRACKET, rect LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, insul .250-20 x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, neg term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . .
. . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, lower front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUARD, splash fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr neck filter fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, front lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, ident diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . .
. . WINDOW, door lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FRAME, support window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHIELD, heat lower LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHIELD, heat lower RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, pos term to rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, caution refer to Owner’s Manual . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, wiring straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, wiring offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, conduit convoluted 3/4 in 6.35mm mtg hole . . . . . . . . . . . . . .
. . CLAMP, stl cush .187dia x .344mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .562dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .625dia x .468mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .750dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush 1.312dia x .343mtg hole . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, stl cush 1.750dia x .531mtg hole . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, nyl .375 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 40

1
2
1
1
6
1
3
4
4
4
1
4
4
4
1
3
6
1
1
14
1
2
1
2
1
16
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
2
4
2
2
1
2

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-1B. Main Assembly
...
...
...
...
...

1
2
3
4
5

. . . . . . . . . . . . 1448720009309 . .
. . . . . . . . . . . . . . . . . . . 006 086 . .
..............................
. . . . . . . . . . . . 1448200009309 . .
. . . . . . . . . . . . . . . . . . . 138 098 . .

. . . 6 . . . . . . . . . . . . . . . . . . . 192 197
. . . 7 . . . . . . . . . . . . 1187060009309
. . . 8 . . . . . . . . . . . . . . . . . . . 023 313
. . . 9 . . . . . . . . . . . . . . . . . . . 162 625
. . . 10 . . . . . . . . . . . . . . . . . . . 010 863
. . . 11 . . . . . . . . . . . . 1626660009309
. . . 12 . . . . . . . . . . . . . . . . . . . 073 655
. . . 13 . . . . S11 . . . . . . . . . . 118 067
. . . 14 . . . . . . . . . . . . 1371640009309
. . . 15 . . . . . . . . . . . . . . . . . . . 010 497
. . . 16 . . . . . . . . . . . . 1183490009309
. . . 17 . . . . . . . . . . . . 1448300009309
. . . 18 . . . . . . . . . . . . 1448310009309
. . . 19 . . . . . . . . . . . . 1371790009309
. . . 20 . . . . . . . . . . . . 1261620009309
. . . 21 . . . . . . . . . . . . . . . . . . . 151 734
. . . . . . . . . . . . . . . . . . 1065390009309
. . . . . . . . . . . . . . . . . . 1065380009146
. . . . . . . . . . . . . . . . . . . . . . . . . 164 618
. . . 22 . . . . . . . . . . . . 1528460009309
. . . 23 . . . . . . . . . . . . 1532490009309
. . . 24 . . . . . . . . . . . . 1142710009309
. . . 25 . . . . . . . . . . . +1528530010202
. . . 26 . . . . . . . . . . . . 1174860010202
. . . 27 . . . . . . . . . . . . . . . . . . . 122 382
. . . 28 . . . . . . . . . . . . . . . . . . . 108 487
. . . 29 . . . . . . . . . . . . . . . . . . . 163 226
. . . 30 . . . . . . . . . . . . . . . . . . . 021 116
. . . 31 . . . . . . . . . . . . . . . . . . . 004 115
. . . 32 . . . . . . . . . . . . . . . . . . . 021 117
. . . 33 . . . . . . . . . . . . . . . . . . *020 319
. . . 34 . . . . . . . . . . . . . . . . . . . 021 114
. . . 35 . . . . . . . . . . . . . . . . . . . 021 115
. . . 36 . . . . . . . . . . . . 1528450009309
. . . 37 . . . . . . . . . . . . 0280890010202
. . . 38 . . . . . . . . . . . . . . . . . . . 147 913
. . . . . . . . . . . . . . . . . . . . . . . . . 147 912
. . . 39 . . . . . . . . . . . . . . . . . . . 089 178
. . . 40 . . . . . . . . . . . . . . . . . . . 049 170
. . . 41 . . . . . . . . . . . . . . . . . . . 004 130
. . . 42 . . . . . . . . . . . . 1214130010202
. . . 43 . . . . . . . . . . . +1453150010202
. . . . . . . . . . . . . . . . . . 1311870010202
. . . . . . . . . . . . . . . . . . . . . . . . . 146 389
. . . 44 . . . . . . . . . . . . . . . . . . . 147 923
. . . 45 . . . . . . . . . . . . . . . . . . . 119 861
. . . 46 . . . . . . . . . . . . 1198510010202
. . . 47 . . . . . . . . . . . . 1172190010202
. . . 48 . . . . . . . . . . . . . . . . . . . 149 971

BAFFLE, air upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLANK, snap-in 1.500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
See engine manual for replacement parts
BRACKET, mtg air line to alternator . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV
(same as Item 13 Fig 11-1A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR LINE, tank to exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose 3.250-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose 2.062-3.000clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, air cleaner intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, pipe brs nipple hex 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, vacuum air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, hose .750 − 1.750clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR LINE, compressor to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, pipe brs adapter M 3/4NPSM x 26mm x 1.5 . . . . . . . . . .
. . SEAL, ring copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AIR COMPRESSOR, 300cc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHIELD, heat compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENGINE, Deutz dsl elec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STARTER, engine 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SHUTDOWN KIT, rsv type governor . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, upper air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . COMPOUND, sealant material (order by ft) . . . . . . . . . . . . . . . . . . .
. . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAP, rain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning falling equipment can cause serious injury . . . . . .
. . AIR CLEANER, intake (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, dust cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CLAMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAND, mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, air cleaner elb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, access radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, ident engine lube oil only . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, ident oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr 3.000 ID x 3.500mtg hole . . . . . . . . . . . . . . . . . . . . .
. . GROMMET, rbr 2.500 ID x 2.750mtg hole . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, support door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, end baffle air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DOOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, engine LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause serious injury . . . . . . . . .
. . LATCH, paddle series 300 w/lock . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, pipe brs adapter bhd 1/2NPT x 1.500 lg . . . . . . . . . . . . . .

1
1
1
1
1
1
1
1
5
1
1
1
1
3
1
2
2
1
1
1
1
1
1
1
1
5ft
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1

OM-166 941 Page 41

Figure 11-1B. Main Assembly

OM-166 941 Page 42

ST-800 491-B (2 of 2)

74

72

Fig 11-5

73

1

71

15

2

68

65

70
69

67

3

66

65

64

4

63

5

62

61

6

60

21

7

10

55
54
53

58
57
56

59

22

20

8

23

9
10

12

30

52

51

24

19

18

17

50

25

49
48

28
15 14 13
16
27
17
18
26

11
31

47

32

29
33

34

35

46

10

37
38

36

45

39

44

43

42

41

40

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-1B. Main Assembly (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68

. . . . . . . . . . . . . . . . . . . 089 351
. . . . . . . . . . . . 1532480009309
. . . . . . . . . . . . 1528480009309
. . . . . . . . . . . . 1528520009309
. . . . . . . . . . . . . . . . . . . 071 890
. . . . . . . . . . . . 1529040009309
. . . . . . . . . . . . 1528470009309
. . . . . . . . . . . . . . . . . . . 071 730
. . . . . . . . . . . . . . . . . . . 602 246
. . . . . . . . . . . . . . . . . . . 071 731
. . . . . . . . . . . . . . . . . . . 601 945
. . . . . . . . . . . . . . . . . . . 116 707
. . . . . . . . . . . . . . . . . . . 603 110
. . . . . . . . . . . . . . . . . . . 010 858
. . . . . . . . . . . . 0395990009309
. . . . . . . . . . . . . . . . . . . 088 684
. . . . . . . . . . . . 1063940009309
. . . . . . . . . . . . 1178270009309
. . . . . . . . . . . . 1107430009309
. . . . . . . . . . . . 1355720009309

. . . 69 . . . . . . . . . . . . . . . . . . . 118 452
. . . 70 . . . . . . . . . . . . . . . . . . . 131 208
. . . 71 . . . . . . . . . . . . 1448100009309
. . . 72 . . . . . . . . . . . . . . . . . . . Fig 11-5
. . . 73 . . . . . . . . . . . . 1448640009309
. . . 74 . . . . . . . . . . . . . . . . . . . 132 712
. . . . . . . . . . . . . . . . . . . . . . . . . 119 836
. . . . . . . . . . . . . . . . . . . . . . . . ♦041 481
. . . . . . . . . . ES1 . . . . . . . . . ♦034 074
. . . . . . . . . . . . . . . . . . . . . . . . ♦083 859
. . . . . . . . . . . . . . . . . . . . . . . . ♦195 754
. . . . . . . . . . . . . . . . . . . . . . . . ♦046 410
. . . . . . . . . . . . . . . . . . . . . . . . ♦035 325
. . . . . . . . . . S8 . . . . . . . . . . ♦021 467
. . . . . . . . . . . . . . . . . . . . . . . . ♦021 385
. . . . . . . . . . . . . . . . . . . . . . . . ♦020 185

..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..

FITTING, pipe brs plug hexhd 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . .
BAFFLE, lower air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRACKET, oil neck w/cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIPE, oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLAMP, hose 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, oil filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . .
WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WASHER, flat stl .656 ID x 2.250 OD . . . . . . . . . . . . . . . . . . . . . . . . .
SCREW, cap stl hexhd .625-18 x 4.000 . . . . . . . . . . . . . . . . . . . . . . .
SUPPORT, front engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOSE, nprn .500 ID x .687 OD (order by ft) . . . . . . . . . . . . . . . . . . .
CLAMP, hose .500-.906clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, brs barbed M 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . . . . . .
VALVE, ball bronze 1/2thd female . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, stl flrd conn M 1/2tbg x 1/2tbg . . . . . . . . . . . . . . . . . . . . . .
FITTING, pipe stl tee F 1/2NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING, brs flrd conn M hd 1/4tbg x 1/8NPT . . . . . . . . . . . . . . . . .
HOSE, oil 47.000 3/4 swivel both ends
(same as Item 29 Fig 11-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, adapter oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STOP, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE, cooling compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, air lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIPE, muffler extension elb 1.875 OD . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .875 OD x .563 ID x .875 lg . . . . . . . . . . . . . . . . . . . . . .
. . STARTING AID, diesel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . VALVE, ether (diesel starting aid) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRACKET, mtg fuel filter/quick start . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, atomizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ATOMIZER, .125 L elbow orf 12 o’clock from inlet . . . . . . . . . . . .
. . . . LABEL, ether starting aid caution etc . . . . . . . . . . . . . . . . . . . . . . .
. . . . SWITCH, tgl SPST 3A 250V off-none-(on) spd term . . . . . . . . . .
. . . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, pipe brs elbow st 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
4
2
1
4
4
4
4
1
2ft
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-166 941 Page 43

1
2

3*

5
6

24

25
7

23

22
21
8
9

20
4

10

19
9
11
18

17 16 15

14
13

12

*Includes Item 4
Figure 11-2. Panel, Front w/Components

OM-166 941 Page 44

ST-800 490-A

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-2. Panel, Front w/Components (Fig 11-1A Item 75)
. . . 1 . . . . S9 . . . . 1346300009880 . . SWITCH, range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . 1183400010202 . . PANEL, front upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . R1 . . . . . . . . . . . 072 462 . . POTENTIOMETER, w/shaft lock (consisting of) . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . . . . 072 590 . . . . LOCK, shaft pot .375-32 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . S4 . . . . . . . . . . . 011 611 . . SWITCH, tgl DPDT 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . S5 . . . . . . . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . S1 . . . . . . . . . . . 172 070 . . SWITCH, ignition 5posn w/out handle . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . . . . . . . . . . . . . . . 021 385 . . BOOT, tgl switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating (order by model and NSPR number) .
. . . 10 . . . . . . . . . . . . . . . . . . . 125 707 . . LEVER, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . FG . . . . . . . . . . 118 066 . . GAUGE, fuel elec 12V neg grd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . V2 . . . . . . . . . . . 164 747 . . METER, volt batt chg 8-18 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . OG . . . . . . . . . . 129 870 . . GAUGE, pressure oil 25-30PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 128 829 . . KIT, oil line 44.000 in 1/8NPT x 10mm . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . 1298370009309 . . GAUGE/SWITCH, temp oil mech 300deg setting . . . . . . . . . . . . . .
. . . 15 . . . . HM . . . . . . . . . . 118 058 . . METER, hour 12-24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . . . . . . 082 788 . . HOLDER, light ind only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . PL1,3 . . . . . . . . *048 155 . . BULB, incand flg base 12V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . . . . . . 082 789 . . LENS, light ind red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . . . . . . 097 926 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . . . . . . 010 647 . . PIN, spring .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . . . . . . 090 231 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . . . A2 . . . . . . . . . . . 164 875 . . METER, amp DC 50MV 0-1K scale . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . V1 . . . . . . . . . . . 164 872 . . METER, volt DC 0-100 scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and NSPR number) . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . . . . . . 022 289 . . TUBING, stl .312 OD x .187 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
2

*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-166 941 Page 45

8
1

2

9

7

10

6

2

3

4

11

5

12

13
14
10
15

16

1

31
30

17
27

28

29
18

26

19
20

23
25

22

21

24
Figure 11-3. Panel, Lower Front w/Components

OM-166 941 Page 46

ST-147 320-F

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-3. Panel, Lower Front w/Components
(Fig 11-1A Item 66)
. . . 1 . . . . . . . . . . . . 0386120009309
. . . 2 . . . . . . . . . . . . . . . . . . . 601 840
. . . 3 . . . . . . . . . . . . . . . . . . . 601 839
. . . 4 . . . . . . . . . . . . . . . . . . . 038 847
. . . 5 . . Neg/Pos . . . . . . . . 038 613
. . . 6 . . . . . . . . . . . . . . . . . . . 038 900
. . . 7 . . . . . . . . . . . . . . . . . . . 602 247
. . . 8 . . . . . . . . . . . . . . . . . . . 605 787
. . . 9 . . . C1,2 . . . . . . . . . . 085 321
. . . . . . . . . . . . . . . . . . . . . . . . . 601 976
. . . . . . . . . . . . . . . . . . . . . . . . . 044 942
. . . 10 . . . . . . . . . . . . . . . . . . . 097 132
. . . 11 . . . . PC3 . . . . . . . . . . 150 415
. . . . . . . . PLG3-5 . . . . . . . . 165 668
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534
. . . 12 . . VR1/R4 . . . . . . . . 046 819
. . . 13 . . . . RC3 . . . . . . . . . . 085 302
. . . 14 . . . . CB3 . . . . . . . . . . 083 432
. . . 15 . . . . PC4 . . . . . . . . . . 152 966
. . . 16 . . . . CB1 . . . 1532470009309
. . . 17 . . . . . . . . . . . . 1502670009309
. . . 18 . . . . . . . . . . . . . . . . . . . 083 030
. . . 19 . . . . . . . . . . . . . . . . . . . 010 915
. . . 20 . . . . . . . . . . . . . . . . . . . 601 836
. . . 21 . . . . . . . . . . . . 0918600009309
. . . 22 . . . . . . . . . . . . . . . . . . . 010 916
. . . 23 . . . . 3T . . . . . . . . . . . 073 873
. . . 24 . . . . . . . . . . . . . . . . . . . 022 289
. . . 25 . . . . . . . . . . . . 1482370009309
. . . 26 . . . . . . . . . . . . 1479080009309
. . . 27 . . . . . . . . . . . . 1224460009309
. . . 28 . . . . . . . . . . . . 0886900009309
. . . 29 . . . . . . . . . . . . 1355720009309

. . TERMINAL ASSEMBLY, pwr output (consisting of) . . . . . . . . . . . . .
. . . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, brs hex .500-13 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUS BAR, term pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TERMINAL BOARD, pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . STUD, brs .500-13 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, lock stl intl tooth .500 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .500-13 x 1.500 (bus bar to terminal) . . . .
. . NUT, locking .500-13 (bus bar to terminal) . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF, 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . .
. . SUPPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, circ 9skt rcpt Amphenol MS-3102A-20-16S . . . . . .
. . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, filter HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, mag SPDT 30A 250VAC . . . . . . . . . . . . . . . .
. . PANEL, front lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STUD, brs grd .250-20 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat brs .250 ID x .625 OD . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, brs hex .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, clamp cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 30A 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, stl .312 OD x .187 ID x .437 lg . . . . . . . . . . . . . . . . . . . . . .
. . COVER, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GAUGE, oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, pipe galv nipple .500NPT x 1.500 lg . . . . . . . . . . . . . . . . .
. . FITTING, stl flrd elbow fem 1/2tbg x 1/2NPT . . . . . . . . . . . . . . . . . .
. . HOSE, oil 47.000 3/4 swivel both ends
(same as Item 70 Fig 11-1B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . . . . . . 039 885 . . CONNECTOR, circ protective cap Amphenol 9760-20 . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident control rating lower
(order by model and NSPR number) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 1577780009309 . . STRAP, grounding (front panel to base) . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 1577920009309 . . STRAP, grounding (front panel to control box) . . . . . . . . . . . . . . . . .

2
4
2
1
1
2
2
2
1
2
2
5
1
3
10
1
1
1
1
1
1
1
5
3
1
3
1
2
1
1
1
1
1
1
1
1
1

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-166 941 Page 47

Item
No.

Dia.
Mkgs.

Part
No.

Description

Quantity

Figure 11-4. Control Box (Fig 11-1A Item 65)
. . . 1 . . . . . . . . . . . . 1186380009309
. . . 2 . . . . T1 . . . . 0700700009309
. . . 3 . . . . RC6 . . . . . . . . . . 090 246
. . . . . . . . . . . . . . . . . . . . . . . . . 079 535
. . . 4 . . . . RC7 . . . . . . . . . . 047 637
. . . . . . . . . . . . . . . . . . . . . . . . . 079 534
. . . 5 . . . . D1 . . . . . . . . . . . 189 701
. . . 6 . . . . . . . . . . . . 1562370009309
. . . 7 . . . . 1T . . . . . . . . . . . 098 828
. . . 8 . . . . . . . . . . . . . . . . . . . 129 524
. . . 9 . . . . . . . . . . . . . . . . . . . 110 375
. . . 10 . . . . PC2 . . . . . . . . . . 160 888
. . . . . . . . . PLG2 . . . . . . . . . 168 071
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066
. . . 11 . . . . PC1 . . . 1337570009309
. . . . . . . . . PLG1 . . . . . . . . . 135 275
. . . . . . . . . . . . . . . . . . . . . . . . . 114 066
. . . 12 . . . . CR1 . . . . . . . . . . 044 588
. . . 13 . . . . CR3 . . . . . . . . . . 059 268
. . . 14 . . . . SR2 . . . . . . . . . . 097 353
. . . 15 . . . . MS1 . . . . . . . . . . 118 072
. . . 16 . . . . . F . . . . . . . . . . *048 317
. . . . . . . . . . . . . . . . . . . . . . . . . 045 852

. . ENCLOSURE, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR w/PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ pin push-in 14-18ga Amp 66359-6 . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . .
. . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term, 10A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TERMINAL, frict .250 x .032 uninsul male . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD, voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . .
. . CIRCUIT CARD, field current regulator . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 20-14ga Amp 350536-1 . . . . . . . . . . . . . .
. . RELAY, encl 12VDC 3PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 120VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DIODE/SCR, bridge intg 2SCR 3 diodes . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, magnetic shutdown 12VDC (consisting of) . . . . . . . . . . .
. . . . FUSE, mintr gl 14A 32V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLIP, component .687dia mtg adh back . . . . . . . . . . . . . . . . . . . . . . .

1
1
1
16
1
14
1
1
1
1
8
1
1
9
1
1
15
1
1
1
1
1
1

1

16
15

14

13
2

12

8
9
11

7

6
5

4

10

ST-800 489

Figure 11-4. Control Box
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 48

3

Item
No.

Part
No.

Description

Quantity

Figure 11-5. Generator (Fig 11-1B Item 72)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

. . . . . . . . . . . . . . . 018 614
. . . . . . . . . . . . . . *151 299
. . . . . . . . . . . . . . . 600 270
. . . . . . . . . . . . . . . 152 044
. . . . . . . . . . . . . . . 049 650
. . . . . . . . . . . . . . . 013 367
. . . . . . . . . . . . . . +140 096
. . . . . . . . . . . . . . . 039 207
. . . . . . . . . . . . . . . 083 751
. . . . . . . . . . . . . . . 024 617
. . . . . . . . . . . . . . . 053 390
. . . . . . . . . . . . . . . 083 748
. . . . . . . . 1450210009309
. . . . . . . . . . . . . . . 601 965
. . . . . . . . . . . . . . . 153 299
. . . . . . . . . . . . . . . 143 220
. . . . . . . . . . . . . . . 004 203

. . BRUSH SET, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOLDER, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CAP, brush holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning moving parts can cause serious injury . . . . . . . . . . . . . .
. . STATOR, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BAFFLE, air generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROTOR, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BEARING, ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FAN, rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STATOR, exciter/endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, .375-16 x 1.000hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENDBELL, generator (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRIP, nyl .050 x 4.000 x 9.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
1
1
1
1
2
1
1
1
1
1
1
1
6
1
1
2

12
9

11
10

7
8

6
1
3

4

2

5

13
16
17

14
15

SD-134 503-C

Figure 11-5. Generator
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-166 941 Page 49

Notes



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : No
Create Date                     : 2003:09:15 14:17:27Z
Modify Date                     : 2003:09:15 09:21:56-05:00
Page Count                      : 56
Creation Date                   : 2003:09:15 14:17:27Z
Mod Date                        : 2003:09:15 09:21:56-05:00
Producer                        : Acrobat Distiller 5.0.5 (Windows)
Author                          : DBENIS
Metadata Date                   : 2003:09:15 09:21:56-05:00
Creator                         : DBENIS
Title                           : o166941c

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