ADOR WELDING LIMITED

OPERATION /
MAINTENANCE
MANUAL

DIESEL ENGINE DRIVEN WELDING SET

MODEL: SILENT CHALLENGER-401

SR. No.: __________________

www.adorwelding.com
CONTENTS
1.0 INTRODUCTION AND TECHNICAL DATA
1.1 SCOPE
1.2 TECHNICAL DATA
1.3 TECHNICAL SPECIFICATIONS

2.0 INSTALLATION
2.1 INSTALLATION OF THE SET

3.0 CONTROLS AND INSTRUMENTS

3.1 ENGINE CONTROLS
3.2 INSTRUMENTS

4.0 OPERATION
4.1 PREPARATION FOR USE
4.2 STARTING PROCEDURE
4.3 GENERAL OPERATION
4.4 TO STOP THE ENGINE
4.5 PRECAUTIONS

5.0 LUBRICATION
5.1 GENERAL LUBRICATION.
5.2 UNDERCARRIAGE LUBRICATION
5.3 ENGINE LUBRICATION

6.0 PREVENTIVE MAINTENANCE

6.1 UNIT MAINTENANCE
6.2 LOG BOOK
6.3 DO'S OF MACHINE OPERATION AND MAINTENANCE
6.4 DON'T OF MACHINE OPERATION AND MAINTENANCE
6.5 PREVENTIVE MAINTENANCE SCHEDULE FOR ENGINE

7.0 OPERATION & SETTING FOR ENGINE CONTROL PCB:

7.1 COMPLETE SET
7.2 ENGINE
7.3 WELDING GENERATOR
7.4 PARTS ORDERING INFORMATION.

8.0 TROUBLE SHOOTING CHART

9.0 SPARE PARTS LIST

10.0 STANDARD SET OF WELDING ACCESSORIES (OPTIONAL)

11.0 GENERATOR WIRING DIAGRAM

12.0 ENGINE CIRCUIT DIAGRAM

13.0 SPARE PART DIAGRAM

www.adorwelding.com
1.0 INTRODUCTION AND TECHNICAL DATA :
1.1 SCOPE

The purpose of this instruc on manual is to inform the operator of the equipment to assist the correct methods of
trouble shoo ng and maintenance. The best results will be obtained only if the operator and maintenance
personnel responsible for the equipment are familiar with those instruc ons.

1.2 TECHNICAL DATA

a) General
The engine powered D.C. Arc Welder, has been developed for electrical welding of steel, cast iron and weld able
nonferrous metals (thickness 0.8 mm onwards) with electrode of 2.5 mm to 6.3 mm diameter. It is useful
especially in remote areas where electrical supply is difficult to get or not available. It can also be used as a standby
welding set in the fabrica on shop.

The standard set is skid mounted. Engine and welding generator are also close coupled to ensure correct alignment
and smooth running. The assembly of engine and generator is mounted on skid. The skid is strong enough for
being towed on cross country roads. The set is covered by a suitable sheet canopy.

All controls and monitoring instruments for engines are brought on panels at various places. This is for easy
opera on and maintenance. Engine exhaust has been brought on the top of the canopy.

b) Engine
The engine is water cooled diesel engine. It is supplied with a heavy duty dry type air cleaner, fuel filter, fuel
li pump, mechanical governor, electric star ng motor, ba ery charging alternator and radiator. The
radiator is of copper/brass fins and with sufficient water capacity for keeping the engine cool. The engine is
protected against high coolant temperature and low lube oil pressure.

c) Auxiliary Power Source :

This is a self-regulated, self-excited A.C. Generator having 415 V/240 V three phase/single Phase AC voltage supply.

d) Controls and Instruments:

The engine, welding generator and auxiliary power source controls and instruments are on front panel.

e) Engine Control and Instruments:

The engine controls and instruments consists of temperature gauges, hour meter, ba ery charging ammeter push
bu on and engine protec on relay.

f) Welding Generator controls and Instruments

These consists of welding current regulator, three output terminals marked III (+), II (+), I (+) and (-) with two
insulated knobs.

g) Auxiliary power source controls

a) Plug/socket for 415 V three phase output.
b) Plug/socket for 240 V single phase output.
c) Miniature circuit breakers for auxiliary output.

OP 911/A

www.adorwelding.com 02
1.3 TECHNICAL SPECIFICATIONS:

MODEL: SILENT CHALLENGER 401

SPECIFICATIONS UNITS VALUES
Welding Generator :
* Welding Current Range Amps (DC) 50-400
Max. hand welding current Amps (DC) 400
at 60 % duty cycle
* Max. hand welding current Amps (DC) 310
at 100 % duty cycle.
* Open circuit voltage (max./min.) Volts (DC) 100/45
*Dia. of coated electrode mm 2.5 to 6.3
* Generally conforms to IS 2635
* Insula on Class Type H
Auxiliary power source :
Ra ng 3 PH./1 PH. KVA 10/3
Voltage V AC 415/240
Phase - 3Ph./1Ph.
MCB AMP 16

Engine :
Make - Simpson
Type Model SJ327T CPCB-II Compliance
Cylinders Nos. 3
Engine cooling Type Water cooled
Rated Engine Speed RPM 1800
Engine ra ng @ 1800 RPM BHP 38.5
Conforms to IS 10002/81
Star ng - Electric
Fuel Consump on Ltrs./Hr. 4
@100% duty cycle
Fuel tank capacity Ltrs. 75

* Welding set is tested for noise level by CPCB - II as per ISO 8582

DIMENSIONS & WEIGHT DETAILS OF SILENT CHALLENGER 401

Type L x W x H ( mm ) Net wt ( kgs) Gross wt (kgs)

a) Silent Challenger 401 1995 x 820 x 1520 1008 1228

(Skid Mounted)

b) Silent Challenger 401 2905 x 1455 x 2100 1148 1368

(2 wheel Mounted)

c) Silent Challenger 401 3435 x 1555 x 2100 1248 1468

(4 wheel Mounted)

OP 911/A

www.adorwelding.com 03
2.0 INSTALLATION:

a) General Installa on:

When installing the set, the loca on should be such as to avoid exposure to high humidity and dust. Moisture condenses on
generator parts and electrical controls causing corrosion which can seriously affect the opera on and efficiency. Care
should be taken for free exhausts. Warm air from radiator side should be allowed to escape freely.

b) Indoor Installa on :
If the unit is to be operated inside the building, be certain that there is proper ven la on to allow exhaust fumes to
escape and ensure inlet of fresh air . Provide at least 3 feet of space on all sides of the unit.

3.0 CONTROLS AND INSTRUMENTS:

3.1 Engine Controls

I. Engines without engine protec on system:

i) MCB : Switch on the MCB to start the engine

ii) Engine Start : To start the engine, press the start push bu on.

iii) Engine stop : Pull engine stop lever ll the engine stop immediately.

II. Engines with engine protec on system

i) Fuel ON/OFF Solenoid: This is 12 Volt solenoid used in engine to operate fuel.
(Energize to run) ON/OFF lever fi ed on F.I.P

ii) Start Key: Rotate the key in clockwise direc on to start the engine & in an clockwise direc on to stop.

Welding Generator Controls

Welding current control regulator: This is provided for controlling the welding current. To increase the current, turn the knob
clockwise and to decrease, turn the knob in an -clockwise direc on. The welding current can be set step less on the regulator
scale plate with three overlapping ranges.

OP 911/A

www.adorwelding.com 04
3.2 Welding Current output terminals and range selec on:

There are three terminals on panel marked Range I, Range II, Range III, (-) and a range selector switch for selec on
of suitable current range. For suitable current range selec on, switch posi on and welding cable connec on
should be as shown below.

i. Range I –Min 50 Amps to 150 Amps

Place range selector switch to posi on as shown and connect welding cables between terminals marked Range I
and (-).

ii. Range II - 70 Amp 240 Amp

Place range selector switch to posi on as shown below and connect welding cables between terminals marked
Range II – Range III and (-).

OP 911/A

www.adorwelding.com 05
iii. Range III - 130 Amp 400 Amp
Place range selector switch to posi on as shown below and connect welding cables between terminals
marked Range II - Range III & (-).

III) Remote Current Control Regulator:

Provision is made for connec ng the remote control regulator on the panel. Remote control regulator
can be used for controlling welding current at a distance from the welding set. Regulator plug should be
inserted in the socket. Place remote/local selector to remote posi on. Set of remote current control regulator
consists of 15 mtrs. long cable and plug. Extra cable length can be supplied with specific order.

3.3 Instruments:

I ) Engine:
I) Warning lamp for ba ery charging failure. This glows in case of some fault in ba ery charging circuit or in
ba ery charging alternator.
ii) MCB: For engine wiring & instrument protec on

II) Welding Generator Instruments (Op onal)

An ammeter to indicate the welding current and a voltmeter to indicate the voltage are supplied in separate
enclosure. The voltmeter on open circuit indicates 45 to 100 volts but should drop to 20-40 volts (Arc Voltage)
while welding.

III) Fuel Gauge:

A fuel gauge is provided on the engine control panel (inside canopy) to check the tank fuel level.

OP 911/A

www.adorwelding.com 06
4.0 OPERATION:
4.1 Prepara on for Use:
1. Close the drain cock of the radiator. Remove the cap of the radiator and fill the radiator with coolant
(an freeze mixture) up to overflow pipe and don't forget to ghten the cap.
2. Check that the storage ba ery is fully charged (to avoid spillage of acid and subsequent damage during
transit, ba ery is provided without sulphuric acid and with dry uncharged plates and accordingly it
requires ini al filling of acid and ini al charge. Tighten loose connec ons if any).
3. Fill engine oil and check the oil level in the crankcase with dips ck provided on the engine (use correct
viscosity grade as per engine manufacturer's recommenda on).
4. Fill the fuel tank with clean filtered diesel. Use high speed diesel for cold weather applica on.
5. Lubricate where required (see lubrica on sec on in engine operator's handbook).
6. Tighten loose electrical connec ons if any.
7. In case of a new set which has been standing idle for a very long me, it is important that the fuel system
may be bled, i.e. for all traces of air to be removed from the fuel line.
8. Be certain that the air passing the cooling fins of the radiator is free from foreign ma er of the radiator
9. Check all nuts and bolts are ght and there is no co on waste, rags etc. in the vicinity.
10. The founda on bolts of the engine and generator are factory set and locked hence they should not
be disturbed.

** IMPORTANT:
Ba ery polarity: This set has been provided with ba ery (-ve) earth system. Make sure that (-ve) nega ve of the
ba ery is earthed to body; otherwise it will burn the ba ery charging alternator components.

4.2 Star ng Procedure:

i) Switch 32 amp MCB to 'ON' Posi on.
ii) Press the push bu on to start the engine.

4.3 General Opera on:

Cau on: Do not change engine speed. Any change from the original factory se ng will degrade the performance.
The engine no low speed is set at 1890 RPM.

Welding:
When the unit is running, the generator voltage with current control regulator at the maximum posi on will give
maximum open circuit voltage. When welding with.electrodes which are connected to the nega ve polarity
(This applies to majority of jobs) the welding cable with electrode holder is connected to the (-) terminal and the
cable with job clamping (earth clamp) component is connected with one of the terminal marked III (+), II (+), I (+)
depending upon the welding current required for the job. When the welding electrode is to be connected to the
posi ve polarity, the welding cables are connected to the terminals in the reverse way as described above.

4.4 Stop the engine:

1) Set without auto shut off arrangement: Pull engine stop lever provided on front panel.

4.5 Precau ons:

1) Don't start the engine on load.
2) Don't stop the engine on load.
3) Keep the generator protec ve cover of the welding generator always closed.
4) Never open the radiator cap when the engine is running. Don't open the cap ll the cooling water gets
sufficiently cooled a er shu ng down the engine.
5) Keep electrode and earthing connec ons ght.
OP 911/A

www.adorwelding.com 07
5.0 LUBRICATION:
5.1 Generator Lubrica on:
Since generator is provided with sealed bearing, no bearing lubrica on is required.
5.2 Undercarriage Lubrica on:
Only the axle bearing, leaf spring and shackles need to be lubricated with grease.
5.3 Engine Lubrica on:
For details of engine lubrica on, see the `User's Manual' furnished with the unit.

6.0 PREVENTIVE MAINTENANCE:

Correct opera on procedure itself is in preven ve maintenance. The recommended opera ng sequences form the basic
pa ern of preven ve maintenance.
Daily checks of vital system and units are recommended both as correct procedures and preven ve maintenance measures.
To get maximum efficiency, low cost of opera on and longer life of your set, par cular a en on should be given in selec ng
high quality engine lubrica on oil of the correct grade.
It is important that the oil filter and air cleaner receive regular periodic a en on and that the level of oil be correctly
maintained. Keep the fan belt properly adjusted to ensure efficient opera on of the fan.

6.1 Unit Maintenance

a) Before Opera on :
i) Fill the radiator with coolant. Check and ghten if necessary all hose connec ons. Make sure that the drain cock
is closed and radiator cap is in locked posi on.
ii) Fill the fuel tank. Be sure that there are no leaks in the fuel lines.
iii) Bring the level of the oil in the crankcase to the full mark of the gauge. Check condi on of oil filter. Use lubrica ng
as per recommenda ons of engine manufacturer. Consult engine manual.
iv) Add sufficient dis lled water to the ba ery for using the level (10 mm approx.) above the plates.
v) Inspect all electrical connec ons and ghten if necessary.
vi) Check the condi on of air filter and ensure its proper moun ng.

b) During Opera on:

i) Ba ery Charging Ammeter: Check the ba ery charging ammeter while the unit is running to determine if the charging
generator is func oning.
ii) Warning Lamp: This should glow when switch is on posi on and engine is not running and it should be off when engine is
running. This indicates healthy condi on of the ba ery charging. Warning lamp glows when ba ery charging circuit is not
func oning.

c) A er Opera on :
i) Clean up around the working area. Put all the tools, parts in their proper places.
ii) Shut the engine and clean it. Wipe out dust scale, or dirt around the welding generator and the exposed electrical
connec ons.
iii) Disconnect ground and electrode cable from the machine, coil them and put them in their proper places.
iv) Clean the air filter and refill it.
v) Refill the fuel tank.
vi) Lubricate oil System: Check all oil lines, connec on, fuel filter and pressure gauge.
vii) Engine Electrical System
- Inspect all wires and terminals for damage, wear and looseness.
- Examine and test the start push bu ons and the switches. Test the ac ons of the star ng motor.

NOTE: Please refer engine manual for engine preven ve maintenance procedure.

OP 911/A

www.adorwelding.com 08
6.2 Log Book
It is desirable that the operator should maintain a log book so that reference can be made to total engine
hours par cularly to engine performance. Periodic inspec on, adjustment and replacement of parts should be
recorded

6.3 Do's of Machine Opera on Maintenance

i) Install the machine in well ven lated environment.
ii) Ensure that the operator is aware of the sequence of the opera on.
iii) Use only correct size of supplied welding cables.
iv) Use only genuine spare parts and order as per instruc ons.
v) Check the condi on of air filter elements periodically. Clean / replace the same whenever necessary.

6.4 Don't of Machine Opera on Maintenance

i) Don't keep the protec on covers open.
ii) Don't do grinding work near the generator especially near the end shield side.
iii) Don't run the machine without blowing inside of the generator with compressed air once a week when
installed in dusty environments.
iv) Don't install the machine in inclined posi on.
v) Don't use welding cables without plugs and with bad insula on.
vi) Don't allow welding cables to be loose.
vii) Don't a end to breakdown/repairs without a thorough study of the manual.
Don't remove the ba ery terminal while set is running.

OP 911/A

www.adorwelding.com 09
6.5 Preven ve Maintenance schedule for engine

Preven ve Maintenance schedule

Sr.
Opera ons First
No. Every day or Every 250 Every Every
service at
every 8 hrs hrs 500 hrs 2500 hrs
25/50 hrs.
1 Check the amount of coolant √ √
2 Check the drive belt(s) √ √
3 Clean the sediment chamber
& the strainer of the fuel li √
pump
4 Check the water in the fuel
√ √
pre-filter
5 Renew the fuel filter
√
element(s)
6 Ensure that the atomizers are
√
checked
7 Ensure that the idle speed
(wherever applicable) is
√
checked & adjusted if it is
necessary
8 Check the amount of
√
lubrica ng oil in the sump
9 Check the lubrica ng oil
√ √
pressure at the gauge.
10 Renew the lubrica ng oil √ √
11 Renew the canister of the
√ √
lubrica ng oil filter
12 Clean the air cleaner or
empty the dust bowl of the √
air filter
13 Extremely dusty condi ons √ √
14 Normal condi ons √
15 Clean or renew the air filter
element, if this has not been √
indicated earlier
16 Clean the vent valve of the
√
engine breather system
17 Ensure that the valve p
clearances are checked and √ √
adjusted if it is necessary
18 Ensure that the alternator,
starter motor etc, are √
checked

OP 911/A

www.adorwelding.com 10
7.0 TROUBLE SHOOTING CHART:
7.1 Complete set
a) Engine Fails to Start

Sr. No. Cause Remedy

i) Loose ba ery connec ons Tighten the ba ery connec ons.
ii) Ba ery discharge Get the ba ery discharged.
iii) No fuel in the tank Fill up the fuel in the fuel tank .
iv) Air lock in fuel lines Remove the air lock.
v) Incorrect engine star ng procedure Follow the engine star ng procedure wri en in
Chapter 4.2
vi) Loose connec ons a) Check the connec ons to the start pushbu on.
b) Check the connec ons to engine starter.
c) Check the connec ons to engine switch.
vii) Loose earthing Check if earthing point of engine start/stop solenoid is
properly earthed.
viii) Low oil level in crankcase Fill the recommended oil in crankcase up to the level
Or defect in pressure switch marked on dips ck and check engine oil pressure
(for sets with auto shut off only) switch.
ix) Joints in engine start/ stop solenoid Lubricate the ball joint of engine start/ stop solenoid
x) Loose connec ons of wire Check and replace if necessary.
xi) Defect in relay RL1 Check and repair if necessary.

b) Engine stops during opera on (for sets with auto shut off only)

Sr. No. Cause Remedy

i) Low oil level in crankcase and pressure Fill the recommended grade of oil in crankcase up to
switch trips the level marked on dips ck
ii) Oil line leak Check the oil line rec fy the same if necessary
iii) Low coolant level in radiator and Fill the radiator with coolant/clean so water up to
temperature switch ps the overflow pipe. Tighten the radiator cap

c) Engine fails to produce welding output current

Sr. No. Cause Remedy

i) Fuse Blown Check fuse and replace if necessary

ii) Output terminal connec ons on the
panel are loose Tighten the connec ons and clean the cable plug
iii) Faulty regulator Replace the regulator

If none of the above faults, refer to the welding generator trouble shoo ng sec on.

OP 911/A

www.adorwelding.com 11
7.2 Engine
See engine operator's hand book.

7.3 Welding Generator

a) Fails to generate rated voltage.

Sr.No. Cause Remedy

i) Loose connec ons at regulator Check and ghten if necessary.
(Electronic Controller) PCB.
ii) Remote/Local Switch or regulator pot Find out and replace
defec ve.
iii) No control supply at regulator terminal 1,2,3 Check control transformer, fuse or
of CN5 (17-0-17 V) auxiliary generator output.
iv) If none of theab ove, check field Check and replace if necessary.
winding of main generator. Resistance
should be about 10.5 Ohms at 25 Deg. C.

7.4 Parts Ordering Informa on:

While ordering parts it is necessary to furnish the following details:

i) Serial Number, model and year of manufacture of the set.
ii) Part Number and descrip on as indicated in the part list.
iii) When ordering parts by Telegram or phone, be sure to confirm by le er.
iv) State definite shipping instruc ons on all orders, i.e. Air Freight, Post Parcel, Passenger Train etc.
v) Although full care is taken while packing and dispatching, when any consignment is received, claims should be
filled immediately with underwriters. All such claims must be made within 7 days from the receipt of shipment.
vi) Refer the latest price list only.
vii) In case of doubts, get clarifica on from AWL's Service Centers located in all important towns and major
industrial centers.

IMPORTANT ENVIRONMENTAL SAFETY INFORMATION

Ba ery Disposal:
Disposing ba eries in your general industrial waste may be harmful to the environment. Damaged ba eries should
be enclosed in a container. When disposing of ba eries of any kind, please follow your appropriate local
regula ons. Many solid Waste authority departments can tell you the proper way to recycle or dispose of ba eries.
So there should be proper disposal of damaged/used ba eries or else return it back to the ba ery distributor.
Disposal of Electrical and Electronic Equipment:
Do not dispose of electrical equipment together with normal waste! In observance of European Direc ve
2012/19/EU on Waste Electrical and Electronic Equipment (WEEE), electrical equipment that has reached the end
of its life must be collected separately and returned to an environmentally compa ble recycling facility. As the
owner of the equipment, you should get informa on on approved collec on systems from our local
representa ve. By applying this European Direc ve you will improve the environment and human health!

OP 911/A

www.adorwelding.com 12
8.0 SPARE PARTS LIST :

MODEL: SILENT CHALLENGER 401

SR CKT.
SPARE PART NO. DESCRIPTION QTY./M/C.
NO. REF.
1 S17.01.003.0040 EXCITOR STATOR ASSEMBLY - 1

2 S21.01.007.0882 REGULATOR PCB ASSEMBLY RPA 1

3 S22.74.071.0041 3 PHASE BRIDGE RECTIFIER D1 1

4 S21.03.001.0808 CONTROL TRANSFORMER- ED SET (RG) TX1 1 SET

5 S21.06.002.0116 WIRE WOUND CURRENT SETTING POT 1K 3W RV1 1 SET

6 S21.07.003.0186 4 PIN CONNECTOR J1 1 SET

7 S21.02.004.0198 ROTARY SWITCH SW1 1 SET

8 S21.06.007.0580 W.W. RESISTOR 1 K, 25 W R3 1 SET

9 S12.01.001.0366 BALL BEARING - 1

10 S21.06.007.0579 W.W.RESISTOR 22K, 25 W R1 1

11 S21.07.003.0910 3 PIN SOCKET 240V AC SCO 2 1

12 S21.07.003.0909 3 PIN PLUG 240V AC - 1

13 S15.01.001.0002 OUTPUT TERMINAL ASSEMBLY WITH KNOB - 3

14 S11.09.010.0021 OUTPUT TERMINAL KNOB - 2

15 S17.01.002.0904 REMOTE CONTROL UNIT ASSY - 1

16 S21.07.003.0908 5 PIN SOCKET 415 V 3 PH - 1

17 S21.07.003.0907 5 PIN PLUG 415 V 3 PH - 1

18 S17.01.003.0039 CAPACITOR BANK ASSEMBLY-ED SET (RG) C1,C2,C3 1

19 S21.02.003.0268 MCB -SINGLE POLE MCB1 1

20 S21.02.003.0225 MCB-3 POLE MCB2 1

21 S21.01.001.0291 FUSE HOLDER - 1

22 S21.02.001.0132 GLASS FUSE LINK(SET OF 20 NOS) F1 1

23 S21.02.004.0323 TOGGLE SWITCH DPDT SW2 1

24 S22.43.001.0001 LINE FILTER - 1

25 S17.01.005.2910 BELLOW ASSEMBLY - 1

26 S81.06.007.0855 ENGINE EXHAUST PIPING CAP NUT - 1

OP 911/A

www.adorwelding.com 13
MODEL: SILENT CHALLENGER 401

SR CKT.
SPARE PART NO. DESCRIPTION QTY./M/C.
NO. REF.
27 S17.01.002.0254 BATTERY POSITIVE TERMINAL ASSEMBLY - 1 SET

28 S17.01.002.0255 BATTERY NEGATIVE TERMINAL ASSEMBLY - 1 SET

29 S11.06.007.0027 RADIATOR ASSEMBLY - 1

30 S11.09.012.0097 FUEL PIPE (FILTER TO FEED PUMP) - 1

31 S11.09.012.0096 FUEL PIPE (FILTER TO FIP) - 1
32 S12.10.007.0220 DIESEL FILTER ELEMENT (SECONDARY) - 1
33 S12.10.007.0219 DIESEL FILTER ELEMENT (PRIMARY) - 1
34 S12.10.003.0178 OIL FILTER CANISTER - 1
35 S81.06.008.0488 EXHAUST SILENCER - 1
36 S36.01.007.0003 TEMPERATURE GAUGE - 1
37 S11.09.012.0635 RADIATOR HOSE (INLET) - 1
38 S12.10.001.0209 AIR FILTER SILICON HOSE - 1
39 S12.10.001.0100 AIR FILTER HOSE (ELBOW) - 1
40 S12.07.000.0317 AIR FILTER ELEMENT - 5
41 S12.10.007.0437 FUEL PIPE - 3M
FLEXIBLE PRESSURE PIPE FOR OIL PRESSURE
42 S11.01.003.0298 - 1
GAUGE
43 S12.10.007.0197 MANDATORY ENGINE MAINTENANCE KIT - 1
44 S36.01.007.0083 OIL PRESSURE GAUGE - 1
ANTI-VIBRATION RUBBER MOUNTS(PGS1-B)-
45 S12.27.001.0584 - 2
GEN
ANTI-VIBRATION RUBBER MOUNTS(PGS1-A)-
46 S12.27.001.0586 2
ENGINE
47 S12.10.007.0255 WATER SEPARATOR - 1

48 S15.01.001.0010 FUEL TANK CAP WITH STRAINER - 1

49 S12.10.007.0015 CABLE STOP CONTROL - 1

50 S36.02.002.0192 BATTERY CHARGING AMMETER AM1 1

51 S21.02.004.0017 HOUR METER - 1

52 S21.01.003.0032 PILOT LAMP HOLDER PLH 1
53 S21.01.002.0561 FILAMENT LAMP FL 1
54 S36.01.008.0003 FUEL GAUGE - 1

55 S36.01.008.0007 FUEL GAUGE SENSOR - 1

56 S21.02.004.0732 ENGINE START PUSH BUTTON PB 1

57 S21.02.002.0560 RELAY 12V DC ,70 AMP RL 1
WIRE BOOM AUXILIARYGENERATOR (FOR
58 S17.01.005.2729 - 1
PANEL INSIDE)

OP 911/A

www.adorwelding.com 14
9.0 RECOMMENDED SPARE PARTS LIST FOR 2 YEARS OF OPERATION

SR. NO. DESCRIPTION SPARE PART NO. QTY.

ANTI-VIBRATION RUBBER MOUNTS (PGS1-B)-

01a S12.27.001.0584 2
GEN

ANTI-VIBRATION RUBBER
01b S12.27.001.0586 2
MOUNTS(PGS1-A) - ENGINE

02 ENGINE START PUSH BUTTON S21.02.004.0732 1

03 OUTPUT TERMINAL ASSEMBLY WITH KNOB S15.01.001.0002 6

04 OUTPUT TERMINAL KNOB S11.09.010.0021 4

05 FUEL PIPE S12.10.007.0249 1

FLEXIBLE PRESSURE PIPE FOROIL PRESSURE

06 S11.01.003.0298 1
GAUGE

07 REMOTE CONTROL UNIT ASSY S17.01.002.0904 1

08 RADIATOR HOSE (INLET) S11.09.012.0635 1

09 RADIATOR HOSE (OUTLET) S11.09.012.0636 1

10 AIR FILTER SILICON HOSE S12.10.001.0100 1

11 AIR FILTER HOSE (BELOW) S12.10.001.0209 1

12 MCB -SINGLE POLE S21.02.003.0268 1

13 MCB-3 POLE S21.02.003.0225 1

OP 911/A

www.adorwelding.com 15
 OP 911/A
R3
10.0 GENERATOR WIRING DIAGRAM:

COM L1

L2

L3 }
RANGE 2 AND 3 CHOKE N

RANGE 1

www.adorwelding.com
INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
2021 DATE SIGN.
DRWN. BY 23/01
CHKD. BY
APRD. BY
SCALE:
FILE NAME
WLDG.SET

GENERATOR WIRING DIAGRAM GENERATOR WIRING DIAGRAM &

301 / 401 / 501

DIESEL ENG. DRIVEN

SILENT CHALLENGER

ALL DIMENSIONS IN MM
DSGN 4031/I5/R0 CK94/472/A
PROJECT
MODEL

SUPERSEDES No.

16
11.0 ENGINE CIRCUIT DIAGRAM:

DO NOT SCALE DRG.

SR. DRG.NO./CODE NO. NOS. WT./PC

DESCRIPTION MATERIAL SIZE REMARKS
NO. STANDARD REQ. Kgs.
FINISH

INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
ALL DIMENSIONS IN MM

DATE SIGN.
DRWN. BY
SMOOTH

CHKD. BY
PUNE - 411019
APRD. BY
SCALE:
FILE NAME
ROUGH

PROJECT

MODEL

DSGN 4031/I5/R1

SUPERSEDES No.

OP 911/A

www.adorwelding.com 17
 OP 911/A

www.adorwelding.com
INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
2021 DATE SIGN.
DRWN. BY 23/01
CHKD. BY
APRD. BY
SCALE:
FILE NAME
GENERATOR WIRING DIAGRAM ENGINE CIRCUIT DIAGRAM
301 / 401 / 501

DIESEL ENG. DRIVEN

ALL DIMENSIONS IN MM
WITH AUTO SHUT OFF
DSGN 4031/I5/R0 CK94/456/B
PROJECT WLDG.SET
MODEL SILENT CHALLENGER

SUPERSEDES No.

18
 OP 911/A
325
STOP
STOP 0
26 160
160 RANGE
RANGE II RANGE II
RANGE II
90
90

0
380

12
20 0
HOURS COOLANT TEMP

110
60

190
60
50 60
40
70 0
30 I

MIN
00 00 15
80
20 REMOTE
REM OTE PANEL 70 IIII 00
45 15 90 RANGE III
24
24
10 13 X
100 13 IIIIII
00 MAAX
M CO
COMMON
110
deg .cel CURRENT
30
12.0 SPARE PART DIAGRAM:

FUEL OIL PRESSURE

6 5
4
7
3
8
2
9
1
10
0
2
Kg/cm

E.S.U
BAT CHARGE CURR

30 30

- +

AMP

ENG. MCB

START
1520

www.adorwelding.com
1995 820

INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
NOTE : 2021 DATE SIGN.
DRWN. BY 23/01
IN VIEW OF CONTINUOUS DEVELOPMENT, CHKD. BY
APRD. BY
ADOR WELDING LTD. RESERVES THE RIGHT OF MODIFICATION/CHANGE SCALE:
FILE NAME
IN DIMENSIONS WITHOUT ANY PRIOR NOTICE. SILENT CHALLENGER - 401
WLDG.SET

SC- 401
301 / 401 / 501

DIESEL ENG. DRIVEN

SILENT CHALLENGER

SKID MOUNTED SKID MOUNTED

ALL DIMENSIONS IN MM
DSGN 4031/I5/R0 GA 94/154/A
PROJECT
MODEL

SUPERSEDES No. GA 94/154

19
 OP 911/A
STOP
RA
RANGE
NGE II RANGE II

HOURS COOLANT T EMP

60

50 60
40
70
30
00 00 80
45 15 20 RE
REMMOTE
OTE P ANE L
90 RA NGE III
10
1 00 C OMMON
COMMON
1 10
de g.ce l CURRENT
CURRENT
30

FUEL OIL PRESSURE

6 5
4
7
3
8
2
9
1
10
0
2
Kg/c m

E.S.U
BAT CHARGE CURR

30 30

- +

AMP

ENG. MCB

START
2100

www.adorwelding.com
1455
2905

INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
NOTE : 2021 DATE SIGN.
DRWN. BY 23/01
IN VIEW OF CONTINUOUS DEVELOPMENT, CHKD. BY
APRD. BY
ADOR WELDING LTD. RESERVES THE RIGHT OF MODIFICATION/CHANGE SCALE:
FILE NAME
IN DIMENSIONS WITHOUT ANY PRIOR NOTICE. SILENT CHALLENGER - 401
SC- 401
301 / 401 / 501

DIESEL ENG. DRIVEN

2 WHEEL MOUNTED 2 WHEEL MOUNTED

ALL DIMENSIONS IN MM
DSGN 4031/I5/R0 GA 94/155/A
PROJECT WLDG.SET
MODEL SILENT CHALLENGER

SUPERSEDES No. GA 94/155

20
 OP 911/A
STOP
STOP
RANGE I RA NGE II

HOU RS COOLANT TEMP

60
50 60
40
70
00 00 30
80
45 15 20 REMOTE
REMOTE PA
PANEL
NEL
90 RA NGE III
10
1 00 COMMON
COM MON
110
de g.c el CURRENT
30

FU EL OIL PRESSURE

6 5
4
7
3
8
2
9 1
10
0
2
Kg/cm

E.S.U
BAT CHARGE CU RR

30 30

- +

AM P

ENG. MCB

S TART
2100

1090 1455

www.adorwelding.com
3435

INDEX MOD. NO. DESCRIPTION DATE SIGN. INDEX MOD. NO. DESCRIPTION DATE SIGN.
NOTE : 2021 DATE SIGN.
DRWN. BY 23/01
IN VIEW OF CONTINUOUS DEVELOPMENT, CHKD. BY
APRD. BY
ADOR WELDING LTD. RESERVES THE RIGHT OF MODIFICATION/CHANGE SCALE:
FILE NAME
IN DIMENSIONS WITHOUT ANY PRIOR NOTICE. SILENT CHALLENGER - 401
SC- 401
301 / 401 / 501

DIESEL ENG. DRIVEN

4 WHEEL MOUNTED 4 WHEEL MOUNTED

ALL DIMENSIONS IN MM
DSGN 4031/I5/R0 GA 94/156/A
PROJECT WLDG.SET
MODEL SILENT CHALLENGER

SUPERSEDES No. GA 94/155

21
 OPERATOR'S LOG BOOK
Sr. Total Details of Rou ne / Preven ve
Date Signature Remarks
No. Hours Breakdown work carried out

OP 911/A

www.adorwelding.com 22
 ADOR WELDING LIMITED
WELDING EQUIPMENT GROUP

TEST CERTIFICATE
POWER SOURCE MODEL: SC-401

Specifica on for Power Source: Set Sr. No_____________________

Parameter Value
1) Open Circuit Voltage 100 Volts
2) Current Range 50-400 Amps
3) Maximum con nuous current @60 % DC 400 Amps
4) Maximum con nuous automa c current @ 100 % D.C 310 Amps
5) Rated Speed 1800 (+/-5%) RPM.

This set has been tested for the following tests and found sa sfactory.

A) Insula on resistance test.

B) High voltage test
C) No load test
D) Load test
E) Short circuit test
F) Welding test

For ADOR WELDING LIMITED

In-Charge (I&FIT-SW&CE)

TC 94/319/A

www.adorwelding.com 23
 ADOR WELDING LIMITED
WELDING EQUIPMENT GROUP

PACKING SLIP FOR

DIESEL ENGINE DRIVEN WELDING SET

PRODUCT CODE MODELS SR. NO

F10.33.103.0065 SILENT CHALLENGER 401 (SKID MOUNTED)
F10.33.103.0066 SILENT CHALLENGER 401 ( 2 WHEEL MOUNTED)
F10.33.103.0067 SILENT CHALLENGER 401 (4 WHEEL MOUNTED)

Tick (£)
SR.No. Descrip on Qty/ Mc
CKD DESP. DESP
1. SILENT CHALLENGER 401 1 No.

FITTED WITH 1 No.

A. BATTERY 1 No.
B. AUX. POWER SOURCE 10/3 KVA, 3/1 PHASE 1 No.
C. CAPACITOR ASSY. 1 No.
D. OUTPUT PLUG 1 No.

ALONG WITH
A. OPERATION CUM MAINTENANCE MANUAL 1 No.
B. HAND BOOK FOR DIESEL ENGINE 1 No.
C. TEST CERTIFICATE 1 No.
D. WARRENTY CARD 1 No.
E. REMOTE CONTROL UNIT 1 No.

CHECKED BY: DESPATCHED BY:

DATE: DATE :

PS 529/A

www.adorwelding.com 24
 ADOR WELDING LIMITED
WELDING EQUIPMENT GROUP

PACKING SLIP FOR

DIESEL ENGINE DRIVEN WELDING SET

PRODUCT CODE MODELS SR. NO

F10.33.103.0065 SILENT CHALLENGER 401 (SKID MOUNTED)
F10.33.103.0066 SILENT CHALLENGER 401 ( 2 WHEEL MOUNTED)
F10.33.103.0067 SILENT CHALLENGER 401 (4 WHEEL MOUNTED)

Tick (£)
Sr. No. Descrip on Qty/ Mc
CKD DESP. DESP
1. SILENT CHALLENGER 401 1 No.

FITTED WITH 1 No.

A. BATTERY 1 No.
B. AUX. POWER SOURCE 10/3 KVA, 3/1 PHASE 1 No.
C. CAPACITOR ASSY. 1 No.
D. OUTPUT PLUG 1 No.

ALONG WITH
A. OPERATION CUM MAINTENANCE MANUAL 1 No.
B. HAND BOOK FOR DIESEL ENGINE 1 No.
C. TEST CERTIFICATE 1 No.
D. WARRENTY CARD 1 No.
E. REMOTE CONTROL UNIT 1 No.

CHECKED BY: DESPATCHED BY:

DATE: DATE :

PS 529/A

www.adorwelding.com 25
ADOR WELDING LIMITED

www.adorwelding.com