OM-130 098U “August 2000 Miller == The Power of Blue fm Description cam Big Blue 401DX C OWNER’S MANUAL Viet our woaste at www-MillerWelds.comFrom Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building are welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the U RUEBUU [ze tradition, They're just as committed to providing equipment and service PrSsommanrdrt that meets the high standards of quality and value established in 1929, Working as hard as you do ‘This Owner's Manual is designed to help you get the most out of your a2 peas ses ta Miller products. Please take time to read the Safety precautions. They will Feast sera ania help you protect yourself against potential hazards on the worksite. We've business. ‘made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you Miler is the frst welding figure out what the problem is. The parts list aaupimert, marulacurer will then help you to decide which exact part the 1SO 9001 Qually System you may need to fix the problem, Warranty and Standard. service information for your particular model are also provided, Miler offers @ Technical ‘Manual which provises ‘more deta serdes and parts information for your lint To obtain a Technical 2 ‘Manual, contact your local ‘strut Your asiibutor ee ‘can also supply you wih Wilaing Process Manuals ‘such as SMAW, GTAW, = GuaWy, and GMaWeP Miller Electric manufactures a full line oo of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Miller The Pacer of Bla4 WARNING This product, when used for welding or cutting, produces fumes or {93506 which contain ‘chemicals known to the State of California to cause birth defects and, (California Heatth & Safty Code Section 25249,5 ot seq) & WARNING Battery posts, terminals and related accessories ‘contain lead and lead ‘compounds, chemicals known tothe State of California to cause ccancor and birth defects oF other reproductive hharm. Wash hands after handing. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of is constituents are known tothe Stato of California to cause cancor, birth defects, and other reproductive harm. ‘Tho following terms are Used interchangeably ‘hroughout this mania: Sstok= SMAW TABLE OF CONTENTS ‘SECTION 1 ~ SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. ‘Arc Welding Hazards 13. Engine Hazards 1-4, Addeonal Symbol for Installation, Operation, and Maintenance 1-5. Principal Safety Standards 1-8, EMF Information ‘SECTION 2 - DEFINITIONS 2-1. Symbols And Definitions ‘SECTION 3 - SPECIFICATIONS ........ 341. Weld, Power, And Engine Speciications 3-2. Dimensions, Weights, And Operating Anglos 3-3. Fuel Consumption 3-4, Duty Cyele And Overheating 25. AC Auliary Power 3.6. VotLAmpere Curves 3-7. Optional AC Power Plant Curves ‘SECTION 4 - INSTALLATION 41. Instaling Welding Generator 42. Instaling Mufer Pipe 4.3. Aatvating The Dry Charge Battery 44, Connoctng The Battory 45. Engine Prestart Checks, 448. Instaling Ether Cylinder (Optional Ether Starting Ad) 4-7. Connecting To Weld Output Terminals 48. Selecing Weld Cable Sizos ‘SECTION 5 - OPERATING THE WELDING GENERATOR 5-1. Contls (See Section 5-2) 5-2. Description OF Front Panel Controls (See Section 5-1) 5-3. Remote AV Control ‘SECTION 6 - OPERATING AUXILIARY EQUIPMENT 6-1, 120 Volt And 240 Vot Duplex Receptacles 6-2. Optional Auliary Power Receptactes 5-3, Connecting Optional Ausiary Power Plant ‘SECTION 7 - MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance 7-2. Maintenance Label 7-3. Servicing Ar Cleaner 7-4. Servicing Fuel And Lubrication Systems 7-5. Adjsting Engine Speed 7-6. Overload Protection 7-7. Servicing Optional Etver Staring At 7-8. Inspecting Ang Cleaning Optional Spark Arestor 7-9. Troubleshosting ‘SECTION 8 - ELECTRICAL DIAGRAM ‘SECTION 9 - RUN-IN PROCEDURE 9-1, Wetstacking 9-2. Run-n Procedure Using Load Bank 8-3. Runn Procedure Using Resistance Grid ‘SECTION 10 - AUXILIARY POWER GUIDELINES ‘SECTION 11 - PARTS LIST WARRANTYSECTION 1 — SAFETY PRECAUTIONS - READ BEFORE USING 414. Symbol Usage 4a ‘A. Marks a special safety m Means Warning! Watch Out! There are possible hazards with his procedure! The possible hazards are shown in ‘he adjoning symbols. [FF Means "Note not safety related, 1-2. Arc Welding Hazards |A._The symbols shown below are used throughout this manual to call attantion fo and identify possible hazards. When you the symbol, watch out, and follow the related instructions to avoid the hazard. The safety Information given below is only 2 summary ofthe more complete safety information found in the Safety Standards listed in Section 15. Read and follow all Safety Standards. ‘A. Only qualified persons should instal, operate, maintain and ‘apatrthis unit ‘A. During operation, keap everybody, especially children, away, FR ELECTRIC SHOCK can kill. Touching We electrical parts can cause fatal shocks or severe bums. The electrode and work oct tlectrially Ive whenever the outputs an. The pat power circuit and machine internal circuits are also live when pawer's on. In semiautomale or automate wire welding the ‘wire, wire reel, dive roll nousing, and all metal pars touching the Welding wire are etctcaly ve. incorrectly installed or improperly grounded equipment is ahazar ‘© Donot touch ive elctrcal part. ‘© Wear dry, hole-tee insulating gloves and body protection 1 Insulate yourse rom work ane ground using dy insulating mats ‘or covers big enought prevent any pysial contact wih the work or ground, ‘© Donat use AC output in damp ares, i movernent is conned, ori {hore isa danger of fling '© Use AC output ONLY if required forthe welding process. {© HAC outputs required, use remote output contol present on unt. ‘© Dsconnact Input power or stop engine before instaling or Servicing his equipment. Lackouttagout input power according to (OSHA 28 CFR 1810.147(s00 Safety Standards). ‘© Property install and ground this equipment according to its ‘Owno’ Manual and rational, sate, and local codes. ‘© Always verity the supply ground ~ check and be sure that input ower cord ground wire is propery connected to ground tcminal in Gisconnect box or that cord plug is connected to a properly ‘grounded recepiace outlet. ‘© When making input connections, attach proper grounding conduc- ‘or rst ~ double-check connections, ‘© Frequently inspect input power cor fr damage or bare wiring — replace cord immediatly damaged — are winng can kl Tur of all equipment when notin use. De net use worn, damaged, undersized, or poorly spiced cables, Do net drape cablos over your body Irearth grounding ofthe workpiece is required, ground it dectly witha separate cable ‘© Dono ouch slectrade i you ae in contac with the work, ground, ‘or anather electrode from a diferent machine ‘© Use only welemsinisined equipment. Repat or replace damages paris at once, Maintain unt according to manual ds BA This group of symbols means Waming! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, ang HOT PARTS hazards, Consultsymbols and rlated insirucons below for necessary actions toavod te hazards, ‘© Wear safely hamess i working above floor level ‘© Koop al panels and covers securely in pace. Clamp work cable wih good metabto-metal contact to workpiece forworkable as near the weld as practical ‘© Insulate work clamp wien not connected to workplace to provent contact with any metal abject, + Do not connect mare than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters. ‘© Slop engine on inverter and discharge input capacitors according to insimusons in Martenance Section before touching any pars ARC RAYS can burn eyes and skin. FRAT) Mans nce (ttt ene etre) ys Tatean bur ye a on, Spas of fone «Wer a weling ime te wth a proper hae oer pret eet coe RG 20 ender eae oy Sassy ime «Use pte sos orbaries opr! tr om sh and «eo peeve ting mate tom arb tamer mate- fal woolen ear and ox potion FUMES AND GASES can be hazardous. Wilding prodices fumes and gases. Bresting FR these fumes and gases canbe hazardous to yout a | iam ' Keep yourhead out of the fumes. Do not breathe the fumes, © Hinide, vontiate the area andor use exaust atthe acto remove welding umes and gases. ‘ventilation is poor, use an approved ai-supplied respirator. ‘© Reed the Material Safely Data Sheets (§SOSs) and the ‘manufacturers insructions for metal, consumables, coatings, Cleaners, and degreasers, 1 Workin a confined space only iit is wall ventilated, or while woaring an alr-supplod respirator. Always havea tained wateh- person nearby. Welding fumes and gases can displace ai and ower te oxygen level causing injury or dsth. Be sue the breath ingairis sate ‘© Do notwold in cations near dograsing, leaning, or spraying op- feations, The neat and rays ofthe are can react wth vapors form highly toxic and iritating gases. 1 Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating i removed fom the wela ‘0a, the area is wel vontlatod, and if nocossary, wo wearing an ‘i-suppliedrespiraor. The coatings and any metals containing these elements can give of toxic fumes if welded (0N130 098 Page +FE] WELDING can cause fire or explo- B= sion. Weling on closed containers, such 9s tanks, rus, ips. can cause them bow Up. Spars any of rom he welding are, The ying soaks, hot \woroiece, and hot equment can cause fires and burns. Accidental contact of elecrods to metal abje's can cause Spark expioson, overeating, fe. Check and be su re areas Stebelore dang any wateng ‘Protect yourself and thers frm fying sparks and hot metal 1 Do not weld where fying sparks can sirke flammable materia, ‘© Remove ll fammables within 35 f (10.7 m) ofthe welding are. ‘his snot possible, tghly cover tem with approved covers. © Be alert that welding sparks and hot materials from welding can ‘easly go through smal cracks and openings to adjacent areas, © Wate for fi, ana keep a fee extinguisher nearby. ‘© Be aware hat welding ona celng, floor, bukhesd,o partion can cause fe onthe hidden sce 1 Do not wold on closed containers suchas tanks, drums, o pipes, Unloss they are propery prepared according o AWS F4.1 (S06 Safety Standards), '© Connect work cable to the work as close tothe welding area as practical lo prevent welding curant rom traveling long, possibly "Unknown paths and causing elecrc shock and fie hazards ‘© Do not use welder to thaw frozen pipes. ‘© Remove stick electrode from holder or cutoff welding wie at contact tp when notin use ‘© Wear oisree protective garments such as leather gloves, heavy shit cuflss trousers, high shoes, and a cap © Remove any combustibles, such as a butane lighter or matches, ‘fom you" person before doing any welding. FLYING METAL can injure eyes. [ITA] + wertn.ctioca wie testing. and gira sac cause sparks and fing rat they can tow of sig. ‘© Wear approved safety glasses with sido shields even under your welaing helmet BUILDUP OF GAS can injure or kill. ‘© Shutot shielding gas supply when notin use, ‘© Always ventilate confined spaces of use 3 proved airsupplied respirator. 1-3. Engine Hazards FUEL can cause fre or explosion DL )) «sone ad et ot cco ‘any sparks or open flames. 1 Do not overfl tank — alow room for fuel to expand, ‘© Dono spill. fue is spilled, clean up before starting engine 1 Dispose of rags in a freprool container (0-130 098 Page 2 parts bare-handed. NOISE can damage hearing. Noise from some processes or equipment can damage hearing HOT PARTS can cause severe burns. ‘* Allow cooing period before maintaining ‘© Wear protective gloves. and clothing when working ona hat engine. '* Donot touch hot engine parts or ust welded approved ear protection if nalse love is MAGNETIC FIELDS can affect pacemak- ‘© Pacemaker wearers keep away. “© Wearers should consul their doctor before going near are welding, gouging, or spot welding operations CYLINDERS can explode if damaged. Shielding gas eyliners contain gas under high pressure If damaged, a cylinder can explode. Since 928 cylinders are normally part of the welding process, be sure to reat them careuly. ‘Protect compressed gas cylinders trom excessive heal, machani- cal shocks, slag, open flames, spark, and arcs. ‘stall ylinders in an upright poston by securing to a stationary support or cylinder rack to prevent fang or pping © Keep cyinders away trom any welding oF cther electrical crcl. 1 Never drape @ welding torch over a gas cylinder ‘© Never allow a welding electrode to touch any cylinder. ‘© Never weld ona pressurized cylinder — explosion wil su © Use ont corect sheisng gas cylinders, regulators, hoses, and fi. tings designed for tne specie applieaion; maintain trem ang aseaciated parts in good condition © Tum face away rom valve outlet when opening cyinder valve ‘© Keep protective cap in place over valve except when cylnder isin Use oF connected for use © Read and follow instuctons on compressed gas cylinders, associated equipment, and CGA publication P- Isted in Safety Standards, ‘STEAM AND HOT COOLANT can burn, ‘© possible, check coolant level when engine is 0d avo sealing ‘¢ Always check coolant level at overow tank, present on un instead of radiator (unless tld ttherwise in maintenance section or engine mancal. {Ifthe engine is warm, checking is needed, anc tore i no overiow tank, fll the next two statements, ‘© Wear safety glasses and gloves and puta rag over radiator cap, © Turncapsigly and lt pressure escape slowly before completly removing cap.“4 | MOVING PARTS can cause injury. Keep away from fans, bets, and rotors. ‘© Keep all doors, panels, covers, and guards closed and securely in pace, * Stop engine before instaling or connecting unit © Have onty qualified people remove guards or covers for male tenance and troubleshooting as necessary, © To provent accidental staring during servicing, disconnect negative (-) battery cable from battery, Keep hands, har loose clothing, and :ools away from moving pars. Reinstall panels or guards and clase doors when servicing is finished and before staring engine + Before working on generator, remove spark plugs or injectors to oop engine from Kekng back a staring © Block ytge! so that wil at tum wile working on generator components BATTERY EXPLOSION can BLIND. '¢ Always woar a face shel, rubber gloves, and protective clothing when working on a bate. + Stop engine before disconnecting or connect: ing battery cables or sorvicng baton, Do not allow tots to cause sparks when working on abate. Do not use welder to charge batlaie or jump start voices. Observe correct polity (+ and -) on batteries. Disconnect negative -) cable frst and connect itlast BATTERY ACID can BURN SKIN and EYES. © Donottp baton. ‘© Replace damaged batten. '¢ Flush ayes and skin immeeiatly with water ENGINE EXHAUST GASES can kill. “¢ Use eauipmant ouside in opan wel-ventited ‘fused ina closed area, vont engine exhaust tuts and away fem any bulking ai intakes. ENGINE HEAT can cause fire ‘© Doro! ecto uni on, aver, or near combust surfaces or lammables. ‘© Koop exhaust and exhaust pipes way from fammabies. EXHAUST SPARKS can cause fire. '* Donat lot engine exhaust sparks cause fre. 1* Use approved engine exhaust spark arestorin Fequited areas ~ see applicable codes, 1-4. Additional Symbols For Installation, Operation, And Maintenance FALLING UNIT can cause injury. © Use iting eye to it unit only, NOT running gear, gas cylinders, tale, or any other ‘© Use equoment of adequate capac tot anc supporuni. = fusing tit forks to move unt, be sure forks are ong enough to extend beyond opposite side of unit Bax] FLYING SPARKS can cause injury. ‘¢ Wear a face shild to protect eyes and face ‘¢ Shape tungsten electods only on ginder with proper quads ina safe locaton wearng proper face, hang, and body protecton Sparks can cause fres — keep lammables away. Mili Y OVERHEATING can damage motors. ‘© Turmoffor unplug equipment before staring or stopping eng. + Do not lt lw volage and frequency caused by low engine speed damage oloctic motors, * Do not cannac 0 or 60 Hortz motors othe 100 Hertz recoptacle where applicable (Bai iar oY OVERUSE can cause OVERHEAT- ING. ‘© Atow cooling peros follow rated duty cyte. ‘© Reduce current or reduce duty cycle before staring to weld again {¢ Do not block o ite arow to un. STATIC (ESD) can damage PC boards. ‘© Puton grounded wrist tap BEFORE handling boards or pats ‘¢ Use proper stati-proof bags and boxes to store, move, or ship PC boards, TILTING OF TRAILER can cause injury. ‘© Use tongue jac or blocks to support waight ‘© Property install woking gonerator onto valor according to nsiucions supplied with ral. READ INSTRUCTIONS, ‘© Use only genuine MILLER roplacement pats, ‘© Perform engine maintenance and service according ta this manual andthe engine (0N-130 098 Page 3E H.F. RADIATION can cause interference. y, ‘¢ Hish-frequency (HF) can interfere with radio ravigaton, safely sorvices, computers, and communications equipment ‘© Have only qualfied persons familar with slectroni¢ equipment perform this instalation, ‘Tho sors esponsiteferhavng a qualified elecican prompt ly corect any Interference problem resulting fom the instal tn, © If notited by the FCC about interference, stop using the equpmentat once. Have the instataton regularly checked and maintained © Keep highrequency source doors and panels igh shut, Keep spark gaps at coretsoting, and use grounding and shielding to minimize the possibilty of interference, 1-5. Principal Safety Standards Safety in Wolaing and Cutting, ANSI Standard 249.1, rom American ‘Welang Society, 550 N.W. Leioune Ra, Miami FL 33326. Safely and Health Standards, OSHA 29 CFR 190, from Supernten: dentof Document, U.S. Government Pring Ofc, Washington, 0.C 2oa02, Rocammnded Safe Practices er tho Proparation for Welding and Cut. ting 0f Containors That Have Held Hazardous Substances, American ‘Welding Sooty Standard AWS F.1, fom American Welding Society, ‘550 NIW. Leseune Ro, Mam, FL 3126 [National Electrical Code, NEPA Standard 70, om Natonal Fr Prec jon Assocation, Batterymarch Park, Quincy, MA 02260. 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields ‘Welding cunt, ast tows through welding cables, will cause elect: ‘magnetic felés. There has boon and sil is some cancer about such files. However, after examining more than 500 studios spanning 17 years of research, a special blue ribbon commitise of the National earch Counc concluded that. “The body of evidence, in the commitise’ judgment, nas not éamonstrated that exposure to paver frequency electne and magnetic elds Is a humar-heath hazard However, stuces are sill gong forh and evidence continues fo be ‘examined. Untl the fal conclusions ofthe research are reached, you ‘ay wish to minimize your exposure to electromagnetic flds when welding or cuting Te reduce magnetic fields in the workplace, use the following procedures: (0-130 096 Page 4 ARC WELDING can cause interference. ‘© Electromagnetic energy can interfere with sensitive electronic equipment such as computors and computer-crven equipment such as robots '* Bo sure all equipment in the welding area is slectromagneticaly compatible ‘¢ Te reduce possible interference, keep weld cables as short as possible, close together, and dow low, such as onthe floor. ‘© Locate wolding operation 100 motors from any sensitive oloc- ‘tonic equipment. ‘© Be sure this welding machine is installed and grounded according to tis manual ‘© interference etl occurs, the user must take extra measures Such as moving the welding machine, using shielded cables, Using Ine fer, oF shielding the work area, ‘Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P- ‘tom Compressee Gas Associaton, 1235 Jefferson Davis Highway, Suite S01, ington, VA 22202. Code fr Safety in Welding and Cutting, CSA Standard W'17.2, rom Canadian Standards Assveation, Standards Sales, 178 Rexcsle Boulevard, Rexdale, Ontario, Canada MEW 13. Safe Practices For Occupation And Educational Eye And Face rotoction ANSI Standaré 287 1, ftom American Natonal Standards Institute, 1430 Broadway, New York, NY 10018, Cutting And Welding Processes, NFPA Standaré 518, from National Fre Protection Assocation, Batierymarch Park, Quine, MA 02258, Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Donet col or drape cables arcund your bay 4. Keep welding power source and cables as fer away from operator as practical, 5. Connect work clamp to workplace as close tothe weld as poss: bie, [About Pacemakers: Pacemaker wearers consut your doctor fst. cleared by your doctor, than following the above procedures is racommended.SECTION 1 — CONSIGNES DE SECURITE — LIRE AVANT UTILISATION 14. Signification des symboles a ‘A. Hdentifi un message de sécurité particulier. Signfe Mise on garde ! Soyez vigilant! Cate procécure présonte dos risques de danger !Couxci sont dentfes pardes symboles adjacents eux directives. EF Signe NOTA ; nest pas relat la sécunt 1-2. Dangers relatifs au soudage a l’are ‘A. Les symboles présentés claprés sont utilisé tout au long du présent manuel pour attirer votre attention et Identifier les ris- ‘Ques de danger Lorsque vous voyez un symbole, soyer Viglantet suivez les directives mentionnées afin évitr tout ‘danger. Los consignes de sécurlts présantées claprés ne font {Que résumer information contenue dans las normes de sdcu~ ‘a énumérdes ala section 15. Veullez re et respecter toutes ‘ces normes de sécurité, > Linstallation, utilisation, Fentrtien at les réparations ne doivent tre confies qu’a des personnes qualifges. > ‘Au cours de utilisation, tonir toute personne particuligrement les enfants. cart ot plus FR UN CHOC ELECTRIQUE peut tuer. Un sing conta avo den pins, dectigus gat Eticetode ete cet ge soucans sort sous taneton oss ge topple On, Cgc dove tise ‘oment, En sous fivledevde ie (GRZo ade sor eous tonson Bes mands al nce ou alms 8 1 Ne jamais oucher ts pléces cactiques sous anion. 1 Porlor dos gant olds wlements deprotection sacs ne comport! pas 1 Stacler cola ideo aia ee au rayon taps cu dues moyen = lan stifssriment gr pour emptcher le eovac physique evr ‘eclalece ou tore. 1 Ne passe sr de source dlecraue Acourrt etique dans ies zones Pies dan lesen conins ou ou on agus do tmber ' So srr gune source slocique acowant cigs UNIQUEMENT slo procédé de soudoge be derarde. * Sifuttsaion dune source soctsquo aouratelcique Savio nécos- fave su sur Goa encon de liconrarde ifapparal en et Saupe * Couper famentaton cu arr le motu var o procter staan, Santa nome OSHA 29 CFR 10:01 ae normes da Seu), 1 Towjour vier a eeu cordon dalrartatn = Vento et farsrerque ‘du sectonneur ou que ls fiche dui cordon est raccordee 8 une prise ‘orectement mse ator ‘sein ere appropn et conten ln connexons Vater traquenmant a cocdon falar pou vod al tps en ammage ou sonude ~ femplocer te eardon mmeestoment Sst fndommage—ur cable dénude pout sovequer ue elevecutn, Mette faparei hrs enon quan on ue pas 1 Ne pas slsor dos cle uss, nsormagés o rstournsuisanto Ou 1 Nepasenrouer is otbes story cops, acstnet~no pas uso connectau a pec ou oso Ge au o ae ouoer ects un an elon const avec pie, ato Une eaode plotenant de auve machine Pe ‘Ce groupe da syboles gna Mise en garde | Soyer vig !iy des risques de dange els atx CHOCS ELECTRIQUES, aux PIECES EN MOUVEMENT alu PIECES CHAUDES. Roportaz-vous aux symbols taux drocives c-dessous an do connate los mosures pond pour Sree tout danger tes pices enaommagees. Entreten Tepparll conformément & 58 Fale cte de tau de ago 6 ote un bo ante mit mia vee Tepe a souser habe Ge vavel. sus pes poss sous 1 sae pines de masse quand pas mis a piée peur Syeorl contact Une tension DC importante subsiste a I'intérieur des onduleurs aprés avoir coupé I'alimentation. Couper alimeraton oy poste a charg ls condersaturs ono ‘ammeindigut donala Sooo Mnarance arn Se oher de amp voquer des brilures dans les yeux et MB) surta peau. ae Le reyonrenen ear proc ae souage ace des yore wobes trios meres oral ot Tiaraae] stent do sovoa don bras vse yu tsa Donu Dee encnes so poenposat be sowage + Porter un cae ae soage mri un San ele apron pou po- ears vag vs an pen soudng 0 Fae oe ee ‘ANS Za ee 2 ear ane osname sea) 1 Porter des protections ppreuvés peur be rele sl riveau sone est Febloussement demande aux aa personnes de pas gar are * Ponsr des vterants do protection eons dns une mate aura r- stata fou fans ou eLuna potato ds pls LES FUMEES ET LES GAZ peuvent tre dangereux. ER Lance oni des slo os. anton LES RAYONS DE L’ARC peuvent pro- Zl tintin: a zene eu user un desppement au riveau do Fare pour racuaton dee tdes et ds gaz de sage © Sliavertiton eet nevisart, cle respteur a slmertaton ar + Ure ssn oct emai, SDS oe = rovbtements, es netioyaris ot les dégrasseurs + Travalor ans wn space frm element sl estlen vel. en por lant un regpater 3 almeraon eat Demande: ours unsure Gamer fame des en & prox, Des umees et os gaz de usage four dca shu oy onyre pve Sot presents aueun danger Ne pas souser cars aes ence stués&proximte dopéraons de a= ‘rteago, se notioyogn ou do purston, cacao he ryane 0 Narrdag neon de vapeur tame dea gocher 3 sour dos Atami un reverent als ue acer gaan sokblen vere nose: (0N-130 098 Page 5= Fe] LE SOUDAGE peut provoquer un in- cendie ou une explosion. Sear tanto conde pope Sinelles ne explosion, un surcmierant oun ican. A 0 1 Se protgar et tauts pasonnes dela poston stress stomatal cha ‘Ne pas sucer das un ental es sencolas peuvent ombsr sur dos Senneesntormnnie * Déslncerauas io substances intammables 8 ue dice de 10,7 de ‘des proiactone nomatagues, Basen date es sone an vavar de pate nv Gee = Survilriotdélenchement ncence et enum ent & post sun pene plancner parocusépraton put dé rate ct su 698 corenous formés equ dos rs Nose, tamboors, ou conotes 3 mane quilr nent 8. péparss ‘ovectementcontrmamen& ANS Ft uo" he normes de adc) 1 Branches srl ioe bl rds poste cen zoe de suse our dre ransport fu courant surune tongue datas pa des che frins Inconus évortuols on roveqvant des raquos dlocteculon st ‘+ Nepasulor poste de soudage pour diel dos condtas gos. = Encas conan utltaten, eleva agus dace du porte-dleco- ‘ie ou cosporl ia pore do contact 1 Por os veloants de protcton cepourws chu tes que des gants Pant de sues rater toute substance combustible de vos ches tales (qin alureureu buane ou Ges alums DES PARTICULES VOLANTES Aan peuvent blesser les yeux. ‘+ Lesoudage,fécallemant passage dela pice fla Brose on fl do fer, tle maulage gnéront fos dtncotes ot dos paricaos mataliques vo lant. Pondant ia pede de vtfoldlesoment des souduros, ls Auent de projet du late: LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou méme la mort. + Fama ratentaton a ge tear on cs ae er uur ban aor es espace confnés ous sve Sun ep Tater dasaieson dr hemebae LE CARBURANT MOTEUR peut pro- Voquer un incendie ou une explo- sion. DL otc tg at aver tes ec “© Nope fae le plen en tama te detente ou die am + Napa ete atc str par de espacepar son Tartare ove do tare carro’ lo ou “detracted un kent ge, (0M-130 088 Page 6 DES PIECES CHAUDES peuvent provoquer des brillures graves. 1 Pravor une pode de reteidssement avant deloc- ‘© one os gars et os vtamants do potaton pour ‘+ Nopsstoucnora mans ness pasos crauses mots LE BRUIT peut affecter l'ouie. Le brut dos processus a des éqipemants pout actor Fou. ‘© ora ds protections aprcuwés pour bs rales Tervoa sono eat rp lve @ LES CHAMPS MAGNETIQUES peuvent {e sovdage par pots. "Se goeseneeon Si des BOUTEILLES sont endomma- 5, elles pourront exploser. Dos bouts do gaz protscteur conenrat eu on lune ool et endonmagee ste pat az fnt coral + Progor es bovoles do gaz compriné duno chaleur xcossive, dos hace mésanques, clair Ses fanmes overs, des incall Soe + Placer boutollesdaboit en es fant das un separ statonnake ou ‘ana un pone butaies pouros enpscat de lama 9 ese raweset Tones bouts oignées des ccs de soudage ou aus ccs 1 No jamais plecor une echo do soudage sur uno bouts & gz 1 Une slocrade so soudage ne etait ante en contact vec une Boe 4o gaz protaceur regulators, yaux at on spies raiien ars Facootd conanabes pou ox 1 Nepas tras on foe dela sateen cuenta soupepe dela bau let cqupatentsansoous oles pubszon P= CGA eaunoae das as 1-3. Dangers existant en relation avec le moteur LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brilures. 9 est pretiable de, verter te guide, oe reaementne fosle metered pur er rile ‘© Toujours vatifar fe nvoau de lquce do reoitssemant dans le vase eapane.on (resent) non dane an (ou! me ‘ner anata aeceonmitananoe du anuel a teu) ‘+ Silo moteur est haus et qe liu do re vr, opéorconene 1+ Mote dos nets de scutes gan, placer un torhon sro ‘© Dévsserle ousronlgérement eager a vapeur = onapper avant4] DES ORGANES MOBILES pouvent provoquer des blessures. ‘+ Mabini formas ot fuemont en plac 15 poros. 18 Abierto motour avant nan ou branchor faparl ‘© Demande’ selament aun personal quel rlever es aps outs ule recauramants pur efector, sys Ie de ‘+ Pour empsoer tut cemaageacierel pendants tava one ‘+ Nopasapeocherios main, coveu,vtemants costs ose 1+ unt interven dépces es bogies ou inca po Gera mise 1» Bloque volt moteur pour évter sa oan ors Sune intervention EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. ‘+ Toujours porter uno proicen facale, des gas on Cacttoaue er tarants e protean ore dune {erventon sar sate, "© Aart moteur avant ae branche ode branche les cles do 1+ vor de povoauar dos ncalles ave los outs on van sr 1 Nopasuitsero pos '* Obsowerla polars coecte (+ ot~)surles bates, © Debrancher beng! (-) en promi tu Le retrancher an cer Te ogo pour rage les bat L'ACIDE DE LA BATTERIE peut pro- vVoquer des brillures dans les YEUX et sur la PEAU. LES GAZ D'ECHAPPEMENT DU MOTEUR peuvent provoquer des accidents mortels. + secret toner caa dea zr oe ‘© Ecos dutlsation dans un endo fame svacue ls gaz chops ‘on duro vor err san de onan drs he 0 LA CHALEUR DU MOTEUR peut pro- voquer un incendie. © Nop lace appara su, md Ge sree informatie LES ETINCELLES A L'ECHAPPEMENT peuvent provoquer un incendie. provoquer un nce ‘vorrcaae an guar - 4-4, Dangers supplémentaires en relation avec l'installation, le fonctionnement et la maintenance LA CHUTE DE L’APPAREIL peut blesser “+ Utisetannoas de vag uiavsmont pour sulver (uz remoraue u ures sconces, Snts pour lve apparel ‘+ En ubtsant des fourches de ovage pour déplacer Tun, assure fue les feurches sot sutieamment langues pour depasser du cote Spposé de Tapper LES ETINCELLES VOLANTES ris- quent de provoquer dos blessures. Z| + otra nec pur tiger ange ‘+ Ato Teeewode au tingle uniquoment la meuleuso dco dopo Temp eear oo ‘terme “ 7 signs ote sustance EMPLOI EXCESSIF peut SURCHAUFFER L'EQUIPEMENT. 1+ Récrale courant ul facture marche avant de ‘+ Nopas oosuerles passages dard poste LES CHARGES ELECTROSTATIQUES peuvent endommager les circuits imprimés. ‘© tabela conneon ava bare Inanor dex ens 5 do ples, pour stocker, déplacer ou expédier des cartes do tere avant de UNE REMORQUE QUI BASCULE pout ‘entrainer des blessures, i souten pode a80rconvenblement I 0 ime dus dara an ‘apport LIRE LES INSTRUCTIONS. Lttser seulement es pcos do recha {apr manuel of ata ce motu (0N-130 098 Page 7E LE RAYONNEMENT HAUTE FRE. <2'y)) J] QUENCE (H.F) risque de provoquer des interférences. © Le rajormomert haute téquonco (ME) pou Drover dea nereeness avec les ¢Qiperen ‘services do sécurié ot es ordnatours ‘+ Demander solomon des poses qualifies falas ves des ‘Luss ot ou de fae cogs rapsomor par un dlcrin ual 4+ Sle FC sqnao dos ineartroncos, ator inmddtoment appara 1 focurragldroment a conte eenttondotistaltion Asha hequonce, maton les édstours dune dance corecta tis une tare tatu blngage pour redure Tos naarences 1-5. Principales normes de sécurité Sefetyin Welaing and Cutting, norms ANSI 249.1, de VAmercan Weld ing Society, 550 NW. Lejeune Ra, Mami FL 33128 Solely and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Goverriment Prning Offes, Washington, D.C. 2402. ‘Recommended Sate Practice forthe Preparation fr Welaing and Cut. {ing of Containers That Move Hels Hazardous Substances, nome ANS F4-1. de tAmercan Welding Society, 550 NW. Lejeune Rd, Miami FL 33128 ‘Nationa Electrical Code, NEPA Standard 70, de la National Fire Protec: ‘ion Assocation, Baterymarch Park, Quincy, MA 02259. LE SOUDAGE A LARC risque de provoquer des interférences. 1 Venera elecromagndtque reque de provoquer es nerencen pour Isaupement sletoniges Sable lone ortataurs et equpament oa (© Voter ao» que tu equpamen de zone do soutape Sot compale “© Pours a posal tartrence, marten les cles de suds eau: cous uo poses groupe als posor aust bs que poe $i ox pa to 1+ Voier ssuer8 ue distance de 100 mare de ot daipament loc ‘+ Veter co que co poste do soudap ot pr lisa tore corto ‘+ Encasteréronces ats avoir pss mesures précis, terse bales Ge pms Gu rentes soporte wees Ibadplecument 2 pot, utlaaton de eines sna Tutsaton do {Wes ge igo ola pose de poteciur dane la zone de wave ‘Safe Handing of Compressed Gases in Cylinders, CGA Pamphlet P- Ge la Compressed Gas Assocation, 1295 Jeferson Davis Pgh, ‘Suite 5011 Afington, VA 22202. Régies de sécurté on soudage,coupage el procédés connexes, nome CSAWI7.2, do! Acsocialion canadienne de normalisaon, vente de Formes, 178 Rexdale Boulovars, Rexdale (Ontario) Canada NOW 13, ‘Safe Practices For Occupation And Educational Eye And Face Protec tion, norme ANSI 287 1, de TAmerican National Sandards Insite, 1490 Broadway, Now York, NY 10018. Cutting ard Weling Processes, norme NFPA 51B, dea National Protection Associaton, Batforymarch Park, Quine), MA 02208. 4-6. Information sur les champs électromagnétiques Données sure soudage électrique at sur ls ofets, pour Forganisme, des champs magnétiques basse fréquence Le courant de soudage, pendant son passage dans ls cables de sou age, causera des champs lecromagnesiques. ly a eu tily a encore lun certan souci propos de tel champs. Cependant, apres avoir ex ‘ming pls de 500 études qu ont été fates pendant une période de recherche do 17 ans, un comité spéialruban bleu du National Re Search Council a conclu: “Laceumulation de preuves, suivant le jgementdu comit, n'a pas démontré que Fexposiion aux champs ‘agnétiques et champs électriques & haute fréquence représente un Fisque dla santé humaine”, Tools, des études sont oujurs en cours tt les prowes continent ate examinées. En attendant que les con Cusions finales do la recherche olen étables, il vous serait souhatable de rédure volre expostion aux champs électoragnét ‘ques pendant le soutage ou le coupage (0M-130 088 Page 8 ‘fn deréduiro les champs électromagnétiques dans environnement Ge brava, spectre consignes sulvantes 1+ Garde es cables ersombes en es torsadant ou en les attachant avec du ruban adh 2 Metre tus les cibles du cOté opposé de opérateur 3. Neppas courber pas st ne pas entourer pas les cAbles autour de votre corp, 4 Garderte poste de soudage et es cables le plus lon possible de 5 Rellerlapince de masse le plus prés possible dela zone de soudure. CConsignes relatives aux stimulateurs cardiaques Les personnes qui portent un stiuatew cacéaque doivet avant tout Consuelo dotaur Sous Bes dédaréapte par vote detour et alors recommandé de respecte es consignes ch-dessus.SECTION 2 — DEFINITIONS Fast (Run, Wela! 7 - , Sp Engine & Ren wed | >| show gto) ) | stat Engine we) (pani) tery (Eni) Circuit Breaker Engine 01 © | Check nactors! Eg) crock valve Fuel Protective Earth Pump: ‘Clearance uel (Ground) Poste — Negative w Corstoataines ing Ae Ampores vots PanetLoca a Romero » AY Read Operator's Engine emperture | (> | oun Aternating Ny | Meme ® Time h Hours s ‘seconds Do Not Sich Pantech 14 AY | sine rrase 13] tree Phase s Etver Staring Aid Engine Coolant ‘Temperature (0N-130 098 Page 9SECTION 3 — SPECIFICATIONS 3-44. Weld, Power, And Engine Specifi ai on raeavuitea | Anpesse un Pow Engine Fun capecty seine | ue ate Ta wits, | wa | eon | samen "its : Btn, | ay coy | aSieeaR, | Reco srgaaasy ae, RRB | meine | 3:2. Dimensions, Weights, And Operating Angles oimersione con | ance wan [23 ey a Depth 56 in (1422 mm) N 7 A 23-44 (691 mm) | | & Do not exceed tilt angles or engine —— Dosstesaedgtemnen scares =] eatin ese 4 7, || Do not move or operate unit where Tien Tam A Resa 3 | atanceem 1 | = Lwannoom | ; A =| mearemneranes a c 27 in (686 mm) I] > fF a) saenaream Hoel 7 1 7) een aot Tt, K 51-1/8 in (1299 mm) 8 sna amas M 4 Holes Tite wb N 10 Holes war BOK (0M-130 088 Page 103:3. Fuel Consumption “The curve shows typical uel use e £ ¢& Under wel or power nade g & & Boe 4 757187 200 set iso a0 } 6. 133 160 | ss 117 140 } 454 100 120 + 373 083 100 + 30s 087 oso + 227 980 080 + 151033040 07 017 02a } neo «oso oop Da a 2 80 0 150 200 250 300 350 400 450 500 DC WELD AMPERES AT 100% DUTY CYCLE 3-4,_Duty Cycle And Overheating maps Da 40% Duty Cycle At 400 Ampores dw Xo A Minds Weling 6 Minutes Resing 800 600 500 400 300 250 150 100 10 15 20 25 & 40 50 60 % DUTY CYCLE 100 Duty Cycle is percentage of 10.min- {tes that unt can weld at rated oad ‘without overheating. ‘A. Excooding duty cycle can damage unit and vold warranty, (0M-130 098 Page 11jary Power ‘The ac power curve shows the aux lary power in amperes avalabe at the 120 and 240 vat receptacles. "50 300 125 250 00 200 gs iso 2 to 2 0 a0 0 5 10 20 25 AC AMPERES IN 240V MODE a 10 20 30 40 50 AC AMPERES IN 120V MQDE 3-6. Volt-Ampere Curves ‘The voltampere curve shows the minimum and maximum voltage and amperage output capabities of the welding goneratr. Curves of al other sotings fall between the ‘curves shown, (0M-130 088 Page 12Optional AC Power Plant Curves The ac power curves show te aux lary power in amperes avaiable at ‘he single-phase 120/240 volt or three-phase 240 vol erminal ‘A. 7.5 KVAIKW Single-Phase Auxiliary Power Plant (No Weld Load) 150 o a 30 40 50 AC AMPERES IN 240V MODE 0 20 40 60 50 100 AC AMPERES IN 120V MODE (COMBINED LOADS) 31 AMPERES PER LINE MAXIMUM B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load) 300 250 wy 200 f Ors Ss0 Qe = 50 a 2 4 2c 30 40 5c AC AMPERES (0M-130 088 Page 13SECTION 4 — INSTALLATION .__Installing Welding Generator Airflow Clearance Location 18in (40 mm) 18in ‘in (460 mn (460 mm) 18h s8in soem) (40 me) 4 1 Generator Base J 2. Metal Vohicle Frame 3 Equipment Grounding ‘eminal oR 4 Grounding Catle Use #10 AWG or larger insulates copper wire. ‘A. Hunt does not have GFCI re ceptacles, use GFCI protected extension cord. ectrcaly bond generator ram fo ile. frame. by metao-mete! 2 contact 2 ‘A. Stop engine and et coo! a. Dont blow exhaust toward \, “ir cleanerralr intake J) Tools Needed! =F Rin copped 12-15 080.4 STISE ET /Re S88 as (0-130 088 Page 144-3. Activating The Dry Charge Battery wre Remove battery trom unit Eye Protocton - Safely Glasses Or Face Shiels Rubber Gloves Vent Caps Sulfuric Acid Eletrotte (1.285 Specie Gravty) Js wor Fill each call with electrolyte to bottom of wll (maximum). ‘A. Donnot overt battery cells, ‘Witten minutes and check elacto- Ive level if recessary, ada electro- fy Ij rise to prope level. Reins- {all vert caps. Battery Charger 1 follow all instruc- pplied with battary ‘amperes or 30 minutes at 5 am eres, Disconnect cnarging cables [nd instal ater. z 5" When electrolyte is low, add only distited water to cols to ‘maintain proper love, 5A For 30 Minutes oR LZ WS 20a For 12 Mites “als Nea =s— (0M-130 088 Page 154-4. Connecting The Battery —~ Js connect —\ eet f \ Tools Needes =F 12in 4-5._Engine Prestart Checks CCheck al uids dally. Engine mus be cold and on a level sutace, Follow rur-in procedure in engine ‘manual furbumed ful and ica lectin exhaust pipe during runs, see Section 9 1 Fuel ‘Ad fresh csel uel before starting engine the fst time (see maine hance label for specications). Fil Met tank up to 172 in (13 mm rom tap to allow room for expansion, (Open tit shutoff valve, Do not runout of fuel or air enters fuel system and causes starting problems. See engine manual 1a Bleed air rom fuel system, 2 O41 [After fusing, check oll wih unt on fevel surfaes Hols nat upto full mark on apsick, ads ol see mai tenance label) [To improve cold weather staring | Keep bateryin ood condition Store batteryin warm area off ‘onoreta surface. Use fuel formulated for cold weather (dase! fel can gel old weather. Contact Jocal fet “supplier for” tue in- formation Use correct grade oll for cold ther (0M-130 088 Page 16A. Stop engine. ‘A. Improper handling or expo- sure to ether ean harm your health. Follow manufacture ors safety instructions on cylinder ‘A. Do not use Ether Stating Ald while engine is running pen side doors), 1 Ether Cylinder 2. Nozzle Remove cover and eean eylinder now. 3 Clamp 4 iting 5 cap 6 VaNe Remove cap and clean fing. Inetal cylinder on fing. Tighten clamp. Alor instaling eyinder, wat at feast 10 minutes before using tolet ether particles sete and revert atomizer plugging. Pur cap on fiting when cylinder is removes ‘Open side doo. 1 Bracket Route cables through bracket 2 Positive (+) Weld Output Termnal 3 Negative (-) Weld Output Ter- minal For Stick welding Direct Current Electrode Positve (DCEP), con net work cable (-) terminal and Glectrode holder cable to. (+) termina. For Direct Curent Electrode Noga tive [DCEN), reverse cable connections, If equipped with optional play ‘witeh, connect electrode holder Cablo to Electrode (-) terminal and work cable to Work (terminal For FCAW welding, connect work able (terminal ane wire feeder (able (2) terminal. ose door Tools Needed ain nw. sr0 24 (0M-130 088 Page 174-8. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Ghreult Not Exceeding mig [_wromons [3 | BS | 8 | 5 [aes | den ee [ee 10-07 Oren ‘Weld cable size (AWG) is based on ether a4 vis or less drop ora current density of atleast 300 creuar mis per ampere. Contact your dis- tnbsor forthe me? equivalent wold cabo sizes, eo (0M-130 088 Page 18Notes (0M-130 088 Page 19SECTION 5 — OPERATING THE WELDING GENERATOR 5-4. Controls (See Section 5-2) (0M-130 088 Page 205-2. Description Of Front Panel Controls (See BW AS Sle EF This unit has a max OCV contol circuit that resets the Amperage/Vottage Con- trol {9 maximum when the are breaks Whan an ars sick wo output contol Fetus to the front pane! or remote con- tro seting. The Amperage/volage Con- trol adjusts amperage only when welding and does not adjust open crc vatage. 1. Ampere Range Switch Use switch to solect wold amperage range, For most welding applications, use lowest amperage range posible fo prevent are ou ages. ‘A. Do not switch under toad. 2 AmporageNtitage Control Control adjusts amperage within. range selecied by Ampere Range swith, Weld out Pulwould bo 140 A DC wih contols sot as Shown (80% of 90 to 190 A) 3 DC Volimeter (Optional) BC Ammeter (Optional) 5 Remote AV Switch And Rocoptacle 5-3, Remote A/V Control (See Section 53) Magnetic Shutdown Switeh (Optional Use evitcn during startup to bypass optional engine shutdown system. System stops en- fie fol pressure Is to ow or all emparature Is too high 7 Engine Control Switch To Start um switch to Start while pressing Shutdown ewieh, Release switches when egestas [Ith engine does not sta, let engine come toa complete stop before attempt lg restart In Run postion, engine runs at welalpower speed. In Rune postion (optional), engine ‘ns al idle speed atno toad and welapower Speed with load apptod. To Stop: turn switen to OF postion. 8 Battery Charging Warning Light Light goes on when battery isnot charging 9 Oil Pressure Waring Light Section 5-1) Light goes on if ol pressure i too low. uit has aliomate shurdown option, light also goes on fol temperature too high. a 10 Stop engine and fix trouble if either Tight goes on. Ethor Starting Aid Switch (Optional) Push switch up and release while cranking fangineto release ether. a " 2 8 “ Do not use Ether if engine is running. Engine Hour Met 01 Temperature GaugelSwter (Optional) 1 Pressure GaugorSuitch (Optional) Polarity Switch (Optional) Paco suite in Straight postion fr electrode negative, or Reverse poston for electrode postive 16 Manual Shutof Lever Use lover to stop engine if engine contol swt does nat work. + AN Conta! Switch Use ewich o select font panel or remote amperage contol 2 Remote NV Receptacle RC3 Connect optional emate cantel to Rea seSvich —> In Example! Range = 80:0 190 A Percentage OF Range = 50% Max = 140 ADC (60% of 80 to 190) Max (140400) 6 Min 6s A0d) Set Range ———J sot Percentage ———— Acjust Oplonal Remote Contal (0M-130 088 Page 21SECTION 6 — OPERATING AUXILIARY EQUIPMENT ‘A. Ifunit does not have GFCIro- coptacies, uso GFCI-pro- tected extension cord ‘Auxiiary power isnot affected by weld outout {7 orcuit breaker continues fo ‘pen, contact Factory Aish: rnzod Sonic Agont 4) 240\V 15 AAC Receptacle Ret 1 2 2 120V 1SAAC Receptacle RO?’ Receptacles supply 80 Hz single | 120V 158 / phase power at welipower speed | 240V 130 3 Circuit Broakers C81 And cba, BI and C82 protect the receplaces trom overload. I CBt (9rCB2 opens, RCT and half of RC2 {ooe nakwork, 720 vals may tbe presentat RC Maximum output fom each duplex receptacle is 1.8 KVARW, and 3 KVIVKW. ftom all rocoptacles, Auxiliary power i nol affected by wold output EXAMPLE: If 10 A is drawn from RCI, only 10 Ais avaiable at RC2: (240V x10) + (120Vx5A)= 3.0 RAW =) (0M-130 088 Page 226-2. Optional Auxiliary Power Receptacles PAW ‘A. Hf unt does not have GFCIre- ceptacles, ‘use GFCLpro- tected extension cord EF Aunillry power snot affected by weld ouput Wa crcl breaker continues to ‘open, contact Facto Autho- rized Service Agent. GFCI Receptacle Option 1 tov s5AacGrcI Receptacle GFCIt ‘Auxllary power output and circuit breaker protection isthe same as Standard receptacles (see Section 1), aground autis detected, GFCI Reset bution pops out_and receptacle does hat work. Check for faulty tools plugged in receptacle, Press button fo reset. EF Atleast once @ month, run en- ‘gine a weld/powor speed and ress fst button to vonly GFCI fs working prope. n, British, And South ‘ceptacle Options. 2 240. 10,AAC Australian Ro- Coptacle RI 3 240 Voll43 A AC South ‘ican Receptacle RC1 4 240 Volt 13.A.AC British Receptacle RC RC! supplies 60 Hz single-phase power at weldpower speed. Maxi- frum output fom receptacle = 3 RVARW, 5 Crout Breaker CBt (081 protects RC! ftom overoad. GBI opens, RC1 does not work Press bution to reset breaker (0M-130 088 Page 236-3. Connecting Optional Auxiliary Power Plant % Sans 92 Stipa Prose | ose ae | Sn Vor fons [ 240 ‘nos 3 2 AVAKW 75 10 Freqvoney core Engine Speed 1250 RPM Wax. Fuse Sze | 95 Ampores Teac 42 connects to GROUND stu on font of Jumper 42 connected to 90 at factory ‘A. Stop engine. ‘A. Power and weld outputs are live atthe same time Disconnect or Insulate ‘unused cables. 1 Have quaifled person insta acconting to circuit diagram ‘and Auilary Power Guidelines (Section 10) Remove junction box cover. + Lead 93 eed 92 Lead 91 Lead 42 connects to front pane! (Ground stud 6 Grounding Terminal 7 dumper Lead 42 8 Isolated Neutral Terminal Jumper 42 is connected to lead 90, ‘at factory. Jumper 42 may be dis Connected from neutral fo mest applicable clecical codes. User Supplied Leads 10 Load Terminals Connect leads to termina, 11 Fuses Ft, F2, And F3 1, F2, and F3 protect each load line ‘rom overload, UF Set Engine Control switch to Run when using avellory power Tole Nene — Sip a a (0M-130 088 Page 24SECTION 7 — MAINTENANCE AND TROUBLESHOOTING 7-4. Routine Maintenance Toe done by Fay Auharze Senvon Ager © bh eave canis | fuel nae Secton © 50h Clean Air Fler. ‘See Section 7-3 han Ar Ab ohn el 2 ral ‘erm ® 100h ae foros ord ee Stem | rT connectons. | loose camp ee KL | © 250h Replace “ ‘Check And Uneadabie a Giesn Spar. Labels. ‘Aart. San “ Bb Change or | ae Senne” | QRH Secunta. | ¢ Jee TEE ) \y \t) \ AP Cables © 1000h Blow Out Or ‘ — Service Welding vacuum nie, change Fuel - Ganerator Buses "Bian Hows CA Fries. Seo eae. cette WD Sears OF Bibs dco ru <> man dude Cheek 2) “tromtel heck Belt ‘SLUDGE Tank. See Valve Teron Seaton Pa ctesrance* © 3000h Cleanset Inectors SS (0M-130 088 Page 25NOTE (op | Falowite storage procedure inthe engine owners manual the unit wil rot be is used for an extended period. 7-2._ Maintenance Label DEUTZ F3L1011F DIESEL ENGINE 1 Engine Maal for complete engine foment) sen Ser a Brera Porn Pronto pera Seek Pe ee eee irene in eae (0M-130 088 Page 267-3. Servicing Air Cleaner A Stop engine. 4) AeCleaner 2. Service Incicator (Optional) 3 Window 4 Reset Buton Service air cleaner alement fred band appears inwindow. A green band means. air cleaner Is okay. Press buiton to reset inalato. ‘A. Donot run engine without ar ‘leaner or with dirty element. Clean ar replace element if ty or ‘damaged. Replace element yearly ‘rater sb cleanings, 5 Dust Ejector 6 Dust Cover 7 Element 8 Safety Element (Optional) 9 Body ‘To clean air fier: Woe off cover and body, Remove cover and dump out dust Wipe dust {fom inside cover and body with damp cloth. Remove elemeri(s) landreinetal cover. ‘A. Donotclean housing with ait hose. Clean elements) vith compressed ai only. Keep nozae at least 1 in (25 mm) from ins ment Max. air pressure: 100 psi (690, kPa). Replace elements) if thas holes or damaged gaskets. Reinstall elements) and cover (dust ejector down) Blow Inspect (0M-130 088 Page 277-4. Servicing Fuel And Lubrication Systems “Tools Needed De 76, 118i and tet cool. it Drain Plug OW Fit Cap Primary Fuel Fiter (Fuel Water Separator) Pereock howap Secondary Fuel Filer Fuel Shutoff Vane Ful Line ‘Shidgo Drain Plug To change oll and filter: ‘Sue engine manual To drain water from fuel system: ‘Open primary fuel fer petoock and rain water into metal container, {lose petcock when watertee fuel flows, To replace primary fue! fit: (ose shuto valve and turn fter counterclockwise, Remove fier, [Apply thin coat of fuel to gasket on ‘ew iter Install na itr ard tam Clockwise. Open shutof valve, Bleed arom fuel system accord- ing to engine manual Ingpect fuel tine, and replace if cracked of worn To replace secondary fuel fiter: ‘Soe engine manual To drain sludge from fuel tank: ut metal container under drain, landremove sludge drain plug. Re- instal plug when dene. ‘A. Aftor servicing, start engine nd check fr fuel leaks ‘A. Stop ongino, tighten connec- tons as necessary, and wipe ‘up spilled fuel. Close doors (0M-130 088 Page 287-5. Adjusting Engine Speed El ter tuning engine, check engine ry pp Bd if ar fo lad speed nhs achonetar {Gee table Yor no load speeds. If necessary, ais speed as follows: Start engine and run unl warm. “Ture AmparagelVotage Contal to 100, ‘Standard Medes: 1 Engine Speed Agustment Seren 2. Locking Nut % f Coonan Tan sew rt arg Se lrocopm| nase éaipn gwar 2 Models With Automatic Idle 4250 «pm (Optional) 3 ThoottleRod 4 Locknut Loosen ocknuts. Place engine contol itch in Rurvldl poston, “Tur tht rod unt engin runs at idle speed, Tighten locknus. 5. Engine Speed Adjustment Screw © Locknut Place engine contral switch in Run position, Loasen locknut, Turn sorew unt ‘engine une at welipower speed. ~ ‘Tahtentocknat NN A. Stop engine ‘Models With Automatic lle (Optional) 43 4 Tools Needed TP 48, 80 (0M-130 088 Page 207-6. Overload Protection E a A. Stop engine. i 1 When a fuse opens, usually indicates a more serious prob- om oxsts. Contact a Factory Auborized Senco Agent 4 Magnetic Shutdown Switch St (Optonal) 2. Fuse F (See Parts List) Fuse F protects magnetic shut ‘down ston MS. Fuse F opers, the engine stops. 3. Thole Solenoid Fuse F4 (Optional) Fuse F4 protects the throttle sole noi rom overload an model with ‘automatic lle option. IT fuse Fs ‘pons, tho engine doos not run at idle spoed, Check fuses and replace if oper. “Tools Needed A. Stop engine ‘A. Improper handling or expo- ‘sure to other ean harm your health. Follow manufacture ‘ers safety instructions on eylindr If engine does not statin cold weather check ether eylnder as {allows Remave cylinder from valve 1) Ethor Cynder 2 Valve a Seale Weigh cyngor o soo itis empty. Be sure stomizeris nt plugged and valve iting i clean Replace, cylinder according to Section 46, (0M-130 088 Page 307-8. Inspecting And Cleaning Optional Spark Arrestor an ‘A. Stop engine and et cool 4 Spark Arrestor Tools Needed: = sin 7-9. Troubleshooting 2 Cleanout Plug Remove plug and remove any dit covering leanout hate. 3 Exhaust Pipe Startengine and un ate speed blow out cleanout hole. I notning lowe out af halo, bret cover ond ‘of ‘exhaust pipe with froproot material ‘A. Stop engine and let cool Reinstall cleanout pg, es] Mw A. Welding Trouble ‘No weld eu. Remedy CCheck positon of Ampere Range swith, CCheck postion of eptional Polarity switch Place AV control switch in Panel postion, or place switch in Remote postion and connect Remote Am- perage contol to Remote AVV receptacle RCS (see Section 3). ‘Check and secure connections to Remote AW recepiadle RCS Remove excessive calls ftom weld cables, Disconnect equipment from auxiliary power receptacles during startup, Have Factory Authorized Series Agent check brshes and slip rings, and fel exciton cut Era weld outout Low or high wel output Low open-circuit velage ‘Maxirnum weld ouput only in each am- pere range, Use dy, properly stored electrode ‘Be sure connection to work pece is clean and th (Check and tighten connections both inside and outside unt Have Facioy Authorized Senice Agent check brshes and slip rings, and fel excision cuit (Check contol setings Check engine speod, and adjust i nacessary (see Section 7-5) Ccheck engine speed, and adust i necessary (see Section 7-5), Have Factory Authorzod Service Agent chock intograted rect and resistor R2 or SR2, Amporage!Votiage contol Rt Have Factory Authorized Service Agent check Amperage/Voltage contol R1,capactor C8, diode D8, integrated rector SR&, and cont relay CR (0M-130 098 Page 31B. Auxiliary Power Trouble No ouput at apilany power receptacles Remedy Reset circuit breaker CB1 andlor CB2 (eee Section 6-1 or 6-2) Disconnect equipment from auxiliary power receptacles during star, Have Facioy Authorized Senics Ager check brushes and slp rigs, and fel exciton Great Tow or Figh output al auxiliary power receptacies, Tow output at optional auilary power | Junetion box ‘No aulpat rom optional auliary power plant; weld output ana standard aueliary ower receptacle ouput okay. c. Engine ‘Check engine speed, ad adjust if necessary (soe Section 7-5), Check engine speed, and adjust i necessary (ase Section 7-5), optional remote device Is being used, set AV Contol switch in Remote positon and remota device al ‘maximum (600 Secton 5). If optional remote device not being used, set AV Gontol switch in Panel postion (see Section 5-3) (Check ard replace fuses F1,F2, andlor F3,itnecessary (see Section 73), Have Faciory Authorized Senice Agont check brushes and sip ings CCheck connections to auxiliary powerplant (986 Section 7-3), Check fusos Ft, F2, and F3 and replace i necessary (see Secton 7-3), Trouble Engine does not star, Engine suddenly sop. Remedy {Check ful level. Open fuel valve (S88 Section 45). CCheck optional Magnetic Shutdown swich fuse F and replace if open (eee Section 7-0). (Check battery and replace Frecessary. Check connections to Engine Control switch. ‘Check ol ievel. Optional automatic shuldown system stops engine fl pressure gots to0 low or all temperature ges bo igh ‘See engine manual Have Factory Authorized Service Agent check engine charging system. Check ol level. Optional automatic shutdown system stops engine if ol pressure gets t00 low or oll temperature gots oo high ‘Check optional Magnetic Shutdown swich fuse F and replace W open (eee Secon 7-6), Engine sony stopped: unable to restart engine, ‘Check ful level Open foe valve (eve Section 4-5). Engine doesnot stp when Engine Gon- trolswich Is placed in Of poston ‘Use manual shot lverto stop engine (aes Secon §-1), Check connections to Engine Contrl with, Have Factory Authorized Service Agent check engine fuel solenod Engine romaine at idle speed when Engine Control switch is placed in Run! lala pasion and an ae is stuck (mods with automate iale option only) with automate idle option erly) Ballery dscharges between uses Engine uses of during wunsn porod welstacking occurs, (0M-130 088 Page 32 Engine wil nolan al le speed. (models Have Facioy Authorized Service Agent chock Engine Gonlvelawtch and ila module, (Check throtle solenoid fuse F4, ane replace if open (see Secton 7-8), Have Factory Authorized Service Agent check Engine Control switch and le modulo Make sure Engine Control switch is in OF position when units shut down Clean ba 3 terminals, and posts with baking soda and water solution, rinse with cloar water. Periodically recharge battery (approximately every three mont). Replace bate Dry engine see Section 8 ‘See engine manualSECTION 8 — ELECTRICAL DIAGRAM ‘WARNING BN Figure 8-1. Circuit Diagram For Welding Generator (0M-130 088 Page 33SECTION 9 — RUN-IN PROCEDURE 9-1, Wetstacking 1) Welding Gonerator Run desel engines near rated out ut during turin period to propery Seat piston rings and prevent wel tacking, Soo nameplate oF ating labelto find ratod output IF Do netic engine longer than necessary. Piston rings seat faster engine runs at weld! power rpm. and the welding enorators kept loaded dunn 2 Engine Exhaust Pie \Wetstacking i unbumed fuel and oilin the exhaust pipe and occurs during run-in the engines ran 00 Tong at ight load o° ale rpm. exhaust pipe is ated with a wet, black tarike substance, ry the ‘engine sing one of the folowing 1 ruin procedures. See the engine manual for aden al engine run-in information, (0-130 088 Page 349-2. Run-In Procedure Using Load Bank 5 Sia Wid ar Stop engine. Do not touch hot exhaust pipe, engino pars, or load banklgr, ‘A. Koop exhaust and pipe away {rom flammables. + Load Bank “Tur all load bank switches OFF if readed, connect load bank to 115 vols ac wall receptacle or genera- {or auxiary power recoptace 2. Welding Generator Place A/V range switeh in max! mum positon, AV contel in mini ‘mum poston, and Output Selector ‘Suleh (present) in either DC postion 3 Weld Cables Connect loag bank to generator Weld output terminals using proper Sze weld. cables with correct connectors.” Observe correct polarity Start engine and run for several Set load bank switches and then adjust generator WV contol so ad ‘equals rated generator outpat (soe rameplae) Check generator and load bank meters afer el five minutes then ‘very fteen minutes to be sure {generators loaded propery. >> 17 Check ol love roquenty dur- ing ruin ad ol if rode, [After one hour (ririmum) place AV ‘contra in minimum postion, then {um of load bank to remove loa, Run engine several minutes at no read, ‘A. Stop engine and let cool 4 Engine Exhaust Pipe Repeat procedure if wetstacking is present (0M-130 088 Page 359-3. Run-In Procedure Using Resistance Grid (A. Stop engine ar ‘A. Be not touch hot exhaust pip, angie pars, or ond Sing {Kany exaust an pipe way fom tanmabie. 1+ Ressanes ord Use greed for great ted ot Tum og 2 Weléng Goneatar Face AV rang swith in mas frm poston A cana ln et Tum poston and Supe Sar Suc meen) eer OC 2 vield cates Connect gi generator wot Saptari Sg prope Se Sol cle wh come Coes tr purty ex porta) 4 Vaetr 5 Chmp-OnAnimetr Connect votmet rd arts Show frat pon porate Slat engi and fn fr eoverl Sel gd eviches ard then ast Sevaraar"A cal a0 oad trad penta oa re nent) Chock genertr and meters er Satine ines ton ove teen runes "be sue generar (aaa proper 1 Chock al love frequent dur- ing ruin; ado i roeded, [Aer one hour (minimum), place ‘AN contral in minimum poston, {hen shu down gid io remove load Run engine several minutes at no road [A Stop engine and let cool 8 Engine Exhaust Pipe Repeat procedure if wetstacking is present (0M-130 088 Page 36SECTION 10 — AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 1. Auxllary Power Receptacies “Neual Bonded To Frame 2 %Prong Plug From Case Grounded Equpment 3 2-Prong Plug From Double insulated Equipment Be sure squipmont has. his symbo! ‘andiorwording, 10-2. Grounding Generator To Truck Or Trailer Frame 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use #10 AWG or larger insulated copper wire. ‘A. Ifunit doos not have GF coptacles, use GF {ected extension cord yme to vohicto frame by ‘melalto-metalcontact (0M-130 088 Page 37Equipment Grounding Termnal 2. Grounding Cable Use #10 AWG or larger insulated copper wir, 3 Ground Device ‘A. Ground generator to system fearth ground I supplying power toa premises (home ‘shop, farm) wiring system. Use ground device as stated inoleccal coos, 10-4. How Much Power Does Equipment Require? VOLTS 115 AMPS 45 fe 60 [AMPERES x VOLTS = WATTS. EXAMPLE: Ifa dri uses 4.5 amperes at 115 volts, calculate ts running power Fequitmontin watts, 45Ax118V=520W Tho lead applied by the ei is 520 watts EXAMPLE 2: If three 200 wat od lamps are used wih te dl rom Example 1 4 te incioua loads to calla ota Toad, (200 w + 200 W + 200 9) +520W= 1120 ‘The taal load applied by the these ood lamps and dels 1120 wats. Resisve Load Aight bulb is @ resistive load anc Feces a constant amount of pow 2. NomResistve Load Equipmentwith a motoris none ‘iste load and requires 2oprox ‘mately sx tmes more power wile ‘Stating the motor than when rane ring (200 Section 10-8) 3 Rating Data Rating shows volts and amperes, corals required to tun equipment (0M-130 088 Page 3810-5. Approximate Power Requirements For Industrial Motors Tndusival Motors Rating ‘Starting Watts Running Watts Spit Phase EHP oo 300 \8HP ‘225 500 HP 1800 600 10HP 2100 700 1aHP ars ars capacitor Stanton Run 1aHP 2020 720 1aHP 207s o75 a HP 4500 1400 1HP 100 1800 112 HP 8200 2200 2HP 1osso 2850 HP 15900 3000 SHP 23200 200 | cepactorstar-Capacior Run 12 He ‘100 2000 SHP 23200 000 7 HP 235000 000 sore 48700 1700 | Fan Duy 118 HP +1000 400 16H? 1400 550 He 1850 50 10H 2400 200 124 23500 1100 10-6. Approximate Power Requirements For Farm/Home Equipment FarmiHome Equipment Rating Starting Wats Running Waits Slack Tank boeer 7000 700 Grain Cleaner 14H 1650 650 Portable Conveyor 12H 3400 1000 Grain Elevotor 34H 4400 1400 Mi Cooler 2900 +100 Biker (Vocoum Pump) 2HP 10500 2900 FARM DUTY MOTORS. soHP 1720 720 S16. (29. Comeyors, nee 2678 75 Feed Augers, Ar 4 HP 4500 1400 Compressors) +HP 9100 1600 sap 8200 2200 2HP 10550 2350 aHP ‘5900 23900 SHP 23300 000 High Torue (e.g. Bam 1424p 8100 2000 Cleaners, So Unioders, SHP 23300 000 So Hosts, Bunk Feeders) 7412p 35000 2000 toHP 46700 10700 1204. f Mes 12He 23200 1000 High Presse 18 Galntin 500 3150 50 Washer 2 galimin 50 Pi 4500 1400 2 galmia 700 Pst 8100 1600 Refrigerator or Freazor 3100 00 | Shatow wet Pump 18HP 2150 750 v2HP 3100 1000 | sump Pump 1BHP. 2100 800 12H 3200 1050 (0M-130 088 Page 3010-7. Approximate Power Requirements For Contractor Equipment ‘Contractor Rating Starting Watts Running Watts Tana ba Ta 355 360 89 09 400 vein 600 00 | crcular saw e12in 500 500 Tit in 00 900 etn +400 1400 | Table saw sin 4800 1500 ‘in 6200 1000 Band Saw ‘ain 2500 ‘100 Bench Grinder ein ‘120 720 ein 3900 1400 ‘in 5200 1600 |r Compressor 12HP 000 1000 1HP 000 1500 sane 2200 200 2HP +0500 200 | Electie Chain Saw 12 He, 12 +100 ‘100 2HP. tein ‘100 ‘100 | Elect Timmer Standard 9 350 350 Heavy Duty 12 in 500 500 Eectc Cutvatoe 1oHP 2100 00 Elec. Hedge Trimmer ‘in 409 400 Food Lights HID 125 100 Mal Hate 313 250 Mercury +000 Sodium +400 Vapor 1250 1000 Submersible Pump 400 aph 600 200 Ccontitugal Pump 200 gph 00 500 Floor Palsher 3i4 HP. 18in 4500 +400 HP, 20in 6100 1600 | Hioh Pressure Washar vee 3180 950 aH 4500 +400 HP 6100 1600 5 gal um Mixer sane +800 00 Wet & Ory Vac sae 00 900 27a He +200 +900 (0M-130 088 Page 40. Power Required To Start Motor 4 oe + MotorStet Code ; 2 2. Running Amporage fee za | APS 25=¢— 2 Rursing pera coDe [Hz 60 4 Motor Voage He ae | PHASE 1 “of staring amperage ‘Step 4: Find code an se tabi to - find KAM Wage i nt Ine multpiyrnnng amperage by sb ne sartng amperage Bp Stop 2: Find Motor HP and Vos ‘Stop 3: Dstrmine staring oper N U age (eee amps). Wilding generator amperage out polis! be atleast hee the Single-Phase Induction Motor Starting Requirements foters runing amperage Motor Start Gee | o [ x | stk] el} | wle wane | 63 a0 | eo | woo] 2] 25 [uo KVAIHP XHP_x 1000 VoUTS: [STARTING AMPERAGE EXAMPLE: Caleulat the starting amperage required fr a 280 V, 18, HP motor with a mator start code of Mt Volts = 230 HP-= 1/4 Using Table, Code M ross in KVAHP = 11.2 112e-vex 1000 FERION’ = 122A Starting the motor requires 12.2 amperes. 10-9. How Much Power Gan Generator Supply? 4 LimitLoad To 90% OF ‘Generator Ouput Always stat norresistve (enter) loads in oder rom largest to smal fel, and add resistive loads lst. 2 5 Second Rule Hf motor does not start within 5 seconds, tum off pawer to prevent motor damage. ‘Motor requires more power than generator can Supply. (0M-130 098 Page 4110-10. Typical Connections To Supply Standby Power 7 hil [7 Customersupplied equipment is required if {generator isto supply standby power during ‘emergencies or power outages. \ 240 V —_\ ‘ tempaaven tone [fee Te 2 i \ mov ‘ Oe omy 3 } wy t | |O4 < 1 O° 8 mov : _ wk 320/240 Vo Ty ov eau, mee | aw F caer = 1 Power Company Service Meter 2. Main and Branch Overeurent Protection 3 Double-Pole, Double-Throw Transfer Switch Obtain and install correct swite, ‘Switch rating must be same as or {reaterthan the branch overeurrent protection, 4 Clcult Breakers of Fusad Diseonneet Switch (Obtain and instal coroct atch 5 Extension Cord Select as shown in Section 10-11. 5 Generator Comectons Connect terminals or plug of ace- ‘quate amperage capacity to cor, Flow all applicable codes and safely practices. “Tum of or unplug al equipment connected to generator before starting or stopping engine. When Starting or stopping the engine has low speed which causes low vole ‘age and frequency. 7 Load Connections Item 4 isnot necessary ccut protections ateady present in ‘welding generator auxiliary power output circu (0M-130 088 Page 4210-11. Selecting Extension Cord (Use Shortest Cord Possi 5 (Cord Lengths for 120 Voit Loads ‘A. unit does not have GFCI receptacles, use GFCIprotected extension cord. ‘Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)" ‘AL unit does not ‘Conductor size is based on maximum 2% vokage drop Cord Lengths for 240 Volt Loads have GFCI receptactes, use GFCLprotected extension cord. efamert, |] ona wa) 4 . 8 0 2 “4 3 00 ws0(i08) | mea | 17a) 10000) 7 wo woo) | 207%) | 15006) | woo@D waa) 70 7200 wou | ze | wey | wen | 20a sons 700 aoen | wey | meen | man | aan we 20 2200 zee | wera | een | sce | am 2 3000 vee | mae | ea | say 30 3600 isos) | say | sons | eran 3 7200 ven | may | 205 @ 00 wae | acy | ara ze 00 roa fa2c18) so 3000 ere@s) | 5005) Current ‘Maximum Allowable Cord Length in ft () for Conductor Size (AWG) aumant Load (Watts) ‘4 6 8 10 2 “ 5 7200 vooreia) | 46037) | 225(@4) 200061) 7 7680 woo zea) | soorisa) | soon | zoey 125 Ge) 10 72400 ‘00(2eay | 850,68) | as0(107) | 225065) | 125188) 100081) 6 3600 eoocrasy | asorror | ase | soa | ea 20 (18) 20 +4800 aoa | 27se4 | 7569) | town | e0(e 25 000 asocion, | 256s) | a5ee | 75023) 30 7000 won | ee | woen | 73 3% 400 2017s) | 1608) | 100061) % 9600 ze) | tee | 5e9 o 70,00 zoe | 1258) 50 12,000 175(63) | 100.60) “Conductor size s based on maximum 236 vokage crop (0M-130 088 Page 43,SECTION 11 — PARTS LIST Figure 11-1. Main Assembly (OM-130 088 Page 44tem Dia. Part No. __Mkgs. No. Description Quantity Figure 11-1. Main Assembly 1 134771 .. PLUG, protective .640sq . 2 2 107 972... TANK, fuel (consisting of) 1 3 115.000 .... CAP, fuel large 1 . + 605 288. FITTING, pipe galv plug sahd .250NPT . 1 4 020 185. FITTING, pipe brs elbow st 1/8NPT 1 5 073.432 .. FITTING, brs barbed M 3/16tbg x 1/8NPT 1 6 125 687 .. HOSE, npm SAE .125 ID x 343 OD (order by ft) at 7 125704. FITTING, hose brs splice 1/8tbg 1 8 097 507 .. STRIP, rr adh back 1.125 x 1,000 x 20.500 2 9 188 235 .. UPRIGHT, base center 1 10 017.479 .. SEAL, weather lift eye... 1 1" 411352 || BATTERY, stor 12V 380crk 8Orsv_ 1 2 108084 .. TERMINAL PROTECTOR, ber post mig 2 1B 124941 .. CABLE, bat pos ..... : 1 14 089.914 || BOLT, L stl 312-18 x 10.000 1 15 124668 .. HOLD DOWN, battery 1 16 010.460 .. STUD, st.312-18 x 10.000 1 7 032.453 |. CABLE, bat neg 1 cee + 049026 .. SCREW, M10-1,5 x 25mm hexhd 1 18 +124 766 |. COVER, top 1 19 134792 |. LABEL, warming general precautionary 1 1.20 107 990 |. LABEL, use diesel fuel only ..... 1 24 035 968. | WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk 1 122 108 487 .. LABEL, warming falling equipment can cause serious injury . 2 23 004 130... BRACKET, support door 2 24 173 847... LABEL, diesel engine maintenance 1 225 +. #124687... DOOR, side RH cee 1 #124685... DOOR, side LH 1 168 385... LABEL, waming battery explosion can blind . 1 173 028. RIVET, nyl 250dia x 1.000 ig 6 26 178763 .. PANEL, rear 1 2 1.4162 741. GUARD, belt : : 1 28 146 994 | LABEL, warning moving parts can cause Serious injury 1 29 107 343. |. GROMMET, rbr neck . 1 30 197614 |. AIR BOX 1 31 197 613. AIR CLEANER, intake (consisting of) 1 32 197675 .... DUST EJECTOR, air cleaner 1 33 197 677 .... COVER ASSY, air cleaner 1 34 +. "197 676 ..., ELEMENT, air cleaner . 1 35 9197 679 |... ELEMENT, air cleaner safety 1 36 197 829 |... BRACKET, mig air cleaner 2 37 197 678 .... BODY, air cleaner 1 38 Deleted 39 010.863 .. CLAMP, hose 2.062 - 3.000cip dia 1 40 124985 |. HOSE, air cleaner to engine 1 44 010.862 .. CLAMP, 1.812 2.500clp dia 1 242 + #010089 .. FITTING, pipe brs coupling 1/8NPT .. 1 43 9046 545 |. RESTRICTION INDICATOR 1 44 + #175 465 .. FITTING, pipe brs adapter extender 1/8 x 1/8 120, 1 45 158 610 .. LABEL, waming electric shock and moving parts 2 46 087 336 |. LATCH 2 47 173908 |. BAFFLE, air... : 1 010736 |. TUBING, stl 625 OD x 12ga wall x .625 1 48 173910 .. WEATHERSTRIPPING cee 1 49 173.903 |. ENGINE, Deutz dsl elec 1 PLGS |... 124346 .. HOUSING, plug ny! 8 contact 1 a - 128 287... STUD, adjusting throttle 1 50 127 648 |. CLEVIS, throttle 1 (OM-130 088 Page 46tem Dia. Part No. __Mkgs. No. Description Quantity Figure 11-1. Main Assembly (Continued) e281 ceeeeeeeeseees 127994 .. BALL JOINT, .250-28 1 52 175936 |. ROD, throttle 1 53 126 388 |. NUT, -250-28 LH 1 4 194036 .. BRACKET, arm throttle 1 : + 010021 .. CLAMP, sti cush .562dia x .343mtg hole 1 072.082 .. BUSHING, st! .265 ID x .499 OD x .593 Ig 2 118679 |. SCREW, M6-1.0 x 30, 2 55 125663 .. BALL JOINT, 250-28 LH 1 2.56.0... TS1...., 124974 .. SOLENOID, 12VDC .. : 1 DBT ..Lleesessss. 175.937 .. BRACKET, support solenoid . 1 58 188 246 .. BRACKET, mtg engine RH 1 59 601.945 |. SCREW, cap sil hexhd .625-18 x 4.000 4 60 071731 |. WASHER, flat stl 656 ID x 2.250 OD x .187thk 4 281. .cccessesses, 071890 .. RETAINER, mount eng/gen ..... 4 1622.2 071730. |! TUBING, stl 875 OD x 12ga wall x 2.375" 4 2663..2..2222224, 072.848. TUBING, npr .875 ID x 2,500 OD x 2,000 4 64 173.929 .. BRACKET, mig solenoid 1 65 Figure 11-3 |. GENERATOR 1 66... SHUNT ... 030 084 | SHUNT, meter SOMV 600A 1 2087 ceiseesesserss 188.239... BRACKET, mtg engine LH 1 68 109 591 |. CLAMP, muffler 1.750dia 1 69 124 866 |. PIPE, muffler extension el 1 70 087 341 |. BUMPER, door 1.000 OD x .750 high 4 nm 188 359. BASE, filer fuel (standard models — includes items 72 thru 77) 1 190 926. BASE, filter fuel (models w/ 7.5/10 KVA opt. — incl items 72 thru 77) .. 1 BTR cevieeseeesess 110.069... FITTING, frd brs elbow M 1/4 ..... 1 4106 394 |! FITTING, fird brs conn M HD 1/4 tbg x 1/4 NPT(7.5/10 KVA option) 73 080 389 .... SCREW, 312-18 x 1.000 cap hexhd 2 fe Th ceetesseeses 124607... STRIP, mtg separator fuel 1 ETB ciociccesses, 172684... NUT, .312-18 x.50 hex : 2 276 .ciccsessecsess 179661 ..., BASE, filer wiadapter and vent... 1 7 145282 ||. FITTING, hose brs barbed elb M 5/16tbg x 1/4NPT 1 78 134835 |. HOSE, SAE .312 ID x .560 OD (order by ft) aft 73 010 323. CLAMP, hose .250-.625clp dia 2 2280... 0cescesee, 106.467... FILTER, fuel spin-on... : 1 at 145 283 || HOSE, fuel 10.000 1/4 swivel both ends 1 82 188 250 |. BASE 1 83 010 146. CLAMP, nyl 625 clamp dia 1 84 123784 |. EDGE TRIM, (order by ft) aft 1.85...., TE1...., 038621 .. BLOCK, term 30A 4P .... 1 (038 620 .. LINK, jumper term blk 30, 2 PLG7 |... 135556 |. CONNECTOR & SOCKETS 1 86 | CR98, CR99 4090 104 |. RELAY, encl 12VDC SPST 2 1.87... Idlemod. #142724 .. MODULE, pull to idie 5 pin ...... 1 1188 112.........1 4176775 | BRACKET, mtg comp panel auto idle’. 1 1.89.0... F4 2. 073429... FUSE, mintr gl slo-blo 15A 32V ..... 1 90 #046 432 | HOLDER, fuse mintr 250 x 1.250 panel mig - 1 ot 053.987 |. INSULATION, rectifier 1 92 081 499. BRACKET, mig strip terminal 1 2:93 ...ccctsssss2. #113932... GUARD, panel rept (consisting of) 1 B94.0000000000001, 113.730 °2.. LABEL, waming stop engine before . 1 95... SR1.2,4 ... 035704 |. RECTIFIER, integ 40A 800V 3 96 173.982 |. PANEL, mig components 1 97 17 038621 |. BLOCK, term 30A 4P 1 1.98......D8 ...., 192307 .. KIT, diode wiwashers .... 1 11.99: B1/G1, D8/C9' 189 701 |! DICDE/CAPACITOR BOARD | 2 100 ce 170674 .. CAPACITOR BOARD 1 401 R6 030 844 |. RESISTOR, WW fxd 25W 25 ohm 1 (OM-130 098 Page 47102 +173317 .. PANEL, front lower 1 tem Dia. Part No. __Mkgs. No. Description Quantity Figure 11-1. Main Assembly (Continued) 103 .... CR2 .... 044588 .. RELAY, encl 12VDC 3PDT 1 +104 .2......... Figure 11-2 .. PANEL, front wicomponents . 1 2105 2... CT1... #105370 .. TRANSFORMER, current 1 106 Zz 129074 .. REACTOR 1 407 .... Neg... 097416 |. TERMINAL, pwr output black (consisting of) 1 48. Pos 1+. 097 424. TERMINAL pur output ed (conaetng 1 : ceeseeses 601 879... NUT, stl hex full fluxh 500-13 . : 1 beiiitiirsssssss 601 880... NUT, stl hex jam 500-13 ..... 1 2409 1224174008. BRACKET, mtg switch and output terminals. 1 110 9174010. SWITCH, polarity 1 #059773 .. HANDLE, switch 1 441102 R2;3 1... 128.862 |) RESISTOR, WW adj 375W 50 ohm 2 2112 .2...te.211, 085656 .. STRIP, mig resistor cee 1 113 188 237 |. UPRIGHT, base front 1 114 108 163 |. FRAME, mtg reactor & fuel tank 1 115, 110.089 |: FITTING, brs fird elbow M 1/4tbg x 1/4NPT 2 2 MN6 62022220021, 010314. VALVE, shutoff fuel... covets 1 SANT LILI, 070040 <. BOLT, J stl 250-20 x 2.750, 4 118 089.517 |. STRAP, fuel tank 2 173919 |. KIT, label 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-130 088 Page 48Part No. Description Quantity Optional Equipment (043 096 .. RECEPTACLE KIT, 120V GFCI 1 ENGINE PROTECTION PACKAGE, (consisting of) 042 318 .... AUTOMATIC SHUTDOWN, low oil pres/hi oil temp (see Figure 11-2) ... 1 043 088 |... AUTOMATIC IDLE, (see Figure 11-1) 041 671 |... SERVICE INDICATOR KIT, (see Figure 11-1) 1 cssss+.++, WELDER'S PACKAGE, (includes Engine Protection Package) (consisting of) 042 236... WELD METERS, (see Figure 11-2) 1 041 966 .... POLARITY SWITCH, (see Figure 11-1) .....csccseeseerseteteeesee 1 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. (M130 098 Page 49Figure 11-2. Panel, Front wiGomponentstem Dia. Part No. Mkgs. No. Description Quantity Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 104) 1 ....83 114193... SWITCH, range (Fig 11-3) 1 200.04 ..2.1) 605 960 |. RHEOSTAT, WW 300W 34 ohm 1 3... MS. #011 072 .... SWITCH, magnetic (consisting of) 1 F "048 317 FUSE, mintr gl 148 32V 1 4 ctessess O11 609... SWITCH, tgl SPDT 15A 125V ..- 1 5 032.897 |) RECEPTACLE, tik grd 2P3W 15A 125V" 1 6 .. cB12 139 266 | CIRCUIT BREAKER, man reset 1P 15A 250VAC 2 7... RCt 604 103 .. RECEPTACLE, str dx grd 2P3W 15A 250V 1 025 234°. PLUG, str grd 2P3W 15A 250 1 a1). Re 170901 |. RECEPTACLE, str dx grd 2P3W 15A 125V 1 073690 .. PLUG, str grd 2P3W 15A 125V Arrow Hart 5965V 9 601 836 | - NUT, brs hex 250-20 jam hwy 3 10 083.030 |. STUD, brs grd .250-20 x 1.750 1 TT PLATE, ident control rating (order by model and serial number) 1 TAQ. 4046 559" METER, amp DC 50MV 0-500 . ceeeees 1 B 9046 654. || METER, volt DC 0-100 1 4 021 385 |: BOOT, toggle switch lever 1 2095.200000.00.21' 4129860 |. GAUGE, oll pressure .... 1 $128 829. KIT, oil line 44.000 in 1/8NPT x 1mm. 1 4128 699 «FITTING, pipe brs adapter V@NPT x 2mm 1 26 III. 4129837 |) GAUGE, ‘engine pressure : 1 SATII. 119044 °2 LEVER, switch black 1 20 082 788 |) HOLDER, light ind 2 2149.2°PLA,2 12221 %048 155.) BULB, incand fig base 12V 2 DIB... cessss.2s, 082789... LENS, light ind red... 2 24... HM 145247 |. METER, hour 4-40VDC 1 22 148 723... KNOB, pointer 1 2223200000020) 019754. HANDLE, switch range 1 24 NAMEPLATE, (order by model and serial number) 1 252... 84 176 606 .. SWITCH, ignition 4posn 1 2226.0. oectit1. 127618 .. PANEL, front upper 1 BTL, 189.404.) SPACER, nylon 1 OPTIONAL “Recommended Spare Parts. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. (0M-130 008 Page 51