Marathon Electric Magna Plus 280-430 Frame Especificações

Vanguard 037-08OP-001B Equipment, May-07 Inc. Operation and Maintenance Manual Weld-Deck welding package CPW 125-4 S/N CA00600021 – UP (Weld-D

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 6 Figure 9: Warning, pressurized coolant, hot surface, read the manual; located on underside of radiato

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037-08OP-001B S/N CA00600021 – UP (Weld-deck) 7Genset labels Ether cylinder present, do not smoke inside the genset compartment. Do not smoke while

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SE350VOLTAGE REGULATORINSTRUCTION MANUAL

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 8 Figure 11: Danger, ether cylinder; typical note on ether cylinder—genset. Figure 12: Warning, impro

INTRODUCTIONThe SE350 voltage regulator is an encapsulated electronic voltage regulator that controls theoutput of a brushless AC generator by regulat

The SE350 voltage regulator can be mounted in any plane, following are mounting dimensions.FIGURE 1FUSEA 4 Amp, 250 V, 5 X 20 mm fuse is supplied with

FIGURE 2VOLTAGE ADJUSTThe screwdriver adjustable potentiometer adjusts the generator output voltage. Adjustmentclockwise increases the generator outpu

PRELIMINARY SET-UPEnsure the voltage regulator is correctly connected to the generator. Refer to the specificconnection diagram supplied with the gene

TROUBLESHOOTINGSymptom Cause ActionResidual Voltage -NoOutputResidual voltage at regulator powerinput wires 3 & 4 below 10 V ac.Acceleration time

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 121Appendix C — Welding Power Units • Miller Invision 456MP • Miller XMT 304 The following pages are

OM-193 267H February 2002ProcessesProcessesMIG (GMAW) and Pulsed MIG(GMAW-P) WeldingFlux Cored (FCAW) WeldingDescriptionInvision 456MP(230/460 And 57

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

The following terms areused interchangeablythroughout this manual:Stick = SMAWWARNINGTABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USI

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 9Figure 13: Danger, high voltage; located on main power alternator connection housing—genset. Figure 14

OM-193 267 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswi

OM-193 267 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-193 267 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-193 267 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it f

OM-193 267 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soye

OM-193 267 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-193 267 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne

OM-193 267 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune

OM-193 267 Page 9SECTION 2 – INSTALLATION2-1. SpecificationsInputPowerRated WeldingOutputVoltageRangeMaximumOpen-CircuitAmperes Input At RatedLoad Out

OM-193 267 Page 102-3. Volt-Ampere CurvesVolt-ampere curves show mini-mum and maximum voltage andamperage output capabilities ofunit. Curves of other

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 10Figure 15: Danger, open machinery; located on fuel pump and turbo sides (fuel pump side shown) of rad

OM-193 267 Page 112-5. Selecting a Locationloc_2 3/96 - Ref. 151 556 / 800 611 / 802 3141 Lifting ForksUse lifting forks to move unit.Extend forks be

OM-193 267 Page 122-7. Remote 14 Receptacle InformationSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuit breaker CB2.Ref. 802 3

OM-193 267 Page 132-8. 115 Volts AC Duplex Receptacle and Circuit BreakersST-801 524-B1 115 V 10 A AC ReceptaclePower is shared between duplexreceptac

OM-193 267 Page 142-10. Selecting Input Voltage802 314 / 802 315Y Turn Off welding powersource, disconnect inputpower, and check voltage oninput capac

OM-193 267 Page 152-11. Connecting Input Power801 535-B / 801 822-AY Turn Off welding powersource, and check voltage oninput capacitors accordingto Se

OM-193 267 Page 16SECTION 3 – OPERATION3-1. Front Panel Controls1 Power Switch. The fan motor is thermostaticallycontrolled and only runs when cooling

OM-193 267 Page 173-2. Meter FunctionsThe meters display the actual weld output values for approximately three secondsafter the arc is broken.NOTEMode

OM-193 267 Page 183-3. Example DisplaysAmperage preset display for Stick welding mode.Voltage preset display for MIG welding mode.Display while weldin

OM-193 267 Page 19Turn Output Adjust control toset arc length to 36.>Prg 7 035Al 4043 ArAdapt i ve3-4. Synergic Controls and OverviewControls1 Disp

OM-193 267 Page 203-5. Initial Display, Manual Pulse MIG Mode, MIG Mode, and Stick Mode1 Software Program NumberWhen power is applied, initial dis-pla

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 11General Hazard Information Before you service the equipment or before you repair the equipment, attac

OM-193 267 Page 213-6. Setup ScreensTo access Setup screens: turnwelding power source Off, pressand hold Select push button, turnunit On, and hold pus

OM-193 267 Page 223-7. Choosing Pulse Programs and Setting Parameters>Prg 2 045St Ar /CO2Adapt i veSetting Arc Length:Arc length is adjusted with

OM-193 267 Page 233-8. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-Off Rate

OM-193 267 Page 24SECTION 4 – PROGRAMSSection 4-1 provides basic information on each of the fifteen programs in the unit’smemory. See Section 4-2 for

OM-193 267 Page 254-2. ProgramsProgram 1 –– .035 ER70S–3 Mild Steel –– Recommended Gases: Argon/CO2Gases: Argon/CO2 mixes up to 10% CO2;Argon/O2 mixes

OM-193 267 Page 26Program 3 –– .052 ER70S–3 Mild Steel –– Recommended Gases: Argon/CO2Gases: Argon/CO2 mixes up to 10% CO2;Argon/O2 mixes up to 5% O2I

OM-193 267 Page 27Program 6 –– .045 309L Stainless Steel –– Recommended Gases: 98 Argon/2 CO2Alternative Gases: Argon/CO2 mixes up to 10% CO2;Argon/O2

OM-193 267 Page 28Program 9 –– 1/16 .062 Aluminum 4043 –– ArgonIPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps120 0 258 56 40 2.15 55

OM-193 267 Page 29Program 12 –– .062 Aluminum 5356 –– ArgonIPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps180 0 291 82 50 2.25 652220

OM-193 267 Page 30Program 15 –– .035 Silicon Bronze –– ArgonIPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps120 0 280 37 42 1.30 50118

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 12Trapped Pressure Pressure can be trapped in a hydraulic system. Trapped pressure can cause sudden equ

OM-193 267 Page 31Program 18 –– .062 Metal Core –– Recommended Gases: Argon/CO2Gases: Argon/CO2 mixes up to 20% CO2IPM Trim Peak Amp Background Amp Fr

OM-193 267 Page 32SECTION 5 – MAINTENANCE AND TROUBLESHOOTINGY Disconnect power before maintaining.. Maintain more oftenduring severe conditions.5-1.

OM-193 267 Page 335-3. Removing Right Side Panel and Measuring Input Capacitor Voltage in 230/460 VoltModelsTurn Off welding power source, anddisconne

OM-193 267 Page 345-4. Removing Right Side Panel and Measuring Input Capacitor Voltage in575 Volt ModelsTurn Off welding power source, anddisconnect i

OM-193 267 Page 355-5. Voltmeter/Ammeter Help Displays. All directions are in reference tothe front of the unit. All circuitryreferred to is located i

OM-193 267 Page 365-6. Error Codes1 Program CRC Error2 Program Range ErrorIf either error code appears, resetthe display to factory settings as fol-lo

OM-193 267 Page 37Notes

OM-193 267 Page 38SECTION 6 – ELECTRICAL DIAGRAMFigure 6-1. Circuit Diagram For Welding Power Source (230/460 Volt Models)

OM-193 267 Page 39193 264-A

OM-193 267 Page 40Figure 6-2. Circuit Diagram For Welding Power Source (575 Volt Models)

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 13Clean all electrical connections and tighten all electrical connections. Check the electrical wires d

OM-193 267 Page 41206 318-A

OM-193 267 Page 42SECTION 7 – PARTS LIST. Hardware is common andnot available unless listed.802 316-BFigure 7-1. Complete Assembly

OM-193 267 Page 43DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete AssemblyQuantity1 187 234 COVER, top 1. . . . . . . . . . . . . . . . . . .

OM-193 267 Page 4445 153 169 ACTUATOR, switch 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-193 267 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete Assembly (Continued)Quantity53 181 245 TERMINAL, power output red 1. . . . .

OM-193 267 Page 46Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 10/01Your distributor also givesyou ...ServiceYou always get the f

PRINTED IN USA  2002 Miller Electric Mfg. Co. 1/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

CC/CV and CC ModelsXMT 304(230/460 And460/575 Volt Models)RProcessesDescriptionMultiprocess WeldingArc Welding Power SourceOM-2208 175 493XSeptember 2

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 14Electrical cables and wire-harnesses Do not bend electrical cables or wire-harnesses to a tighter rad

The following terms areused interchangeablythroughout this manual:TIG = GTAWStick = SMAWTABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE

OM-2208 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_7/021-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-2208 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-2208 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-2208 Page 41-4. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 550

OM-2208 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 7/021-1. Signification des symbolesSignifie Mise en garde ! Soyez v

OM-2208 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-2208 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-2208 Page 81-4. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society,

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 15Mounting and Dismounting Do not attempt to mount or dismount the machine between the machine and any

OM-2208 Page 9SECTION 2 – INTRODUCTION 2-1. SpecificationsVoltage Amperage Max. Open-RMS Amps Input at Rated LoadOutput, 60 Hz 3-Phase at NEMA LoadVo

OM-2208 Page 10 2-3. Volt-Ampere Curvesva_curve1 4/95 – SA-178 652 / SA-178 653Volt-ampere curves show minimumand maximum voltage and amper-age output

OM-2208 Page 11SECTION 3 – INSTALLATION 3-1. Selecting a Locationloc_2 3/96 - Ref. ST-151 556 / ST-801 1921 Lifting HandlesUse handles to lift unit.2

OM-2208 Page 12 3-2. Weld Output Receptacles And Selecting Cable SizesY ARC WELDING can cause Electromagnetic Interference.To reduce possible interfer

OM-2208 Page 13 3-3. Remote 14 Receptacle InformationSocket* Socket Information24 VOLTS ACA 24 volts ac. Protected by circuit breaker CB2.AJKI24 VOLTS

OM-2208 Page 14 3-5. Electrical Service GuideY CAUTION: INCORRECT INPUT POWER can damage this welding power source. This welding pow-er source require

OM-2208 Page 15 3-6. Connecting Input Power input_9_99 - Ref. ST-144 221 / Ref. ST-070 399-C / ST-801 192Check input voltage available atsite.. The Au

OM-2208 Page 16SECTION 4 – OPERATION 4-1. Front Panel Controls For CC/CV Model1 Power Switch. The fan motor is thermostaticallycontrolled and only run

OM-2208 Page 17 4-2. Front Panel Controls For CC ModelRef. ST-175 50023 4517 61 Power Switch. The fan motor is thermostaticallycontrolled and only run

OM-2208 Page 18 4-3. Meter Functions For CC/CV ModelThe meters display the actual weld output values for approximately three secondsafter the arc is b

VANGUARD EQUIPMENT, INC. 15627 EAST PINE STREET TULSA, OKLAHOMA 74116, USA ': 918.437.1796 7: 918.437.1794

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 16Do not get onto or off a moving machine. Never jump off the machine. Do not try to get onto or off of

OM-2208 Page 19 4-5. Meter Functions For CC ModelThe meters display the actual weld output values for approximately three secondsafter the arc is brok

OM-2208 Page 20 4-7. Lift-Arc TIG ProcedureWith Process Switch in the Lift-ArcTIG position, start an arc as follows:1 TIG Electrode2 WorkpieceTouch tu

OM-2208 Page 21 5-2. Voltmeter/Ammeter Help Displays. All directions are in reference to the frontof the unit. All circuitry referred to is lo-cated i

OM-2208 Page 22 5-3. Blowing Out Inside Of UnitY Do not remove case whenblowing out inside of unit.To blow out unit, direct airflowthrough front and b

OM-2208 Page 23Notes

OM-2208 Page 24SECTION 6 – ELECTRICAL DIAGRAMS197 550-AFigure 6-1. Circuit Diagram For 230/460 Volt Models

OM-2208 Page 25197 553Figure 6-2. Circuit Diagram For 460/575 Volt Models

OM–2208 Page 26SECTION 7 – PARTS LISTST-801 428-F. Hardware is common andnot available unless listed.1233031323334129383940424950515253565758596061226

OM-2208 Page 27DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 7-1. Parts AssemblyQuantity1 +175 148 WRAPPER 1. . . . . . . . . . . . . . . . . .

OM–2208 Page 28DescriptionPartNo.Dia.Mkgs.ItemNo. Figure 7-1. Parts Assembly (Continued)Quantity36 C3,4 192 935 CAPACITOR, elctlt 2700uf 450V

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 17Equipment Information Section CPW 125–4 Welder Package Specification (All values approximate) Transp

OM-2208 Page 29Notes

OM–2208 Page 30Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2002 Miller Electric Mfg. Co. 6/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 210Appendix D — Genset Engine • Cummins 6BT5.9-G6 The following pages are taken from information publi

©2007 Vanguard Equipment, Inc. All Rights Reserved Printed in Canada

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 18Operation Section Battery Disconnect Switch The battery disconnect switch is in the genset enclosure

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 19Emergency Stop Figure 22: Emergency Stop Button Genset Emergency Stop —Located on the Control/Distrib

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 20Genset Stop/Run/Start Switch STOP — Turn the genset stop/run/start switch to the STOP position in ord

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 21Ether Starting Aid Figure 26: Genset Ether Starting Aid Ether Starting Aid — At temperatures below 0°

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 22Main Supply AC Circuit Breaker DANGER HIGH VOLTAGE: DO NOT OPEN the inner main panel door unless you

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 23Main Supply AC Meters’ Phase Selector Switch Figure 30: Main Supply AC Meters’ Phase Selector Switch

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 24Three Phase Equipment Circuit Breakers and Receptacles Figure 32: Three Phase Equipment Circuit Break

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 25Single Phase Front-Mounted Equipment Receptacles and Circuit Breakers with Ground Fault Circuit Inter

S/N CA00600021 – UP (Weld-deck)i Table of Contents FOREWORD ...

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 26Single Phase Equipment Ground Fault Circuit Interrupters (GFCI)—Connecting To Notice All electrical s

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 27Compressed Air Pressure Gauge Figure 35: Compressed Air Pressure Gauge – located in Control/Distribut

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 28Air Compressor Run Mode Valve – OPTIONAL Note: If this option is not installed, the air compressor’s

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 29Compressed Air Receiver Drain Valve Figure 38: Compressed Air Receiver Drain Valve (shown open) Compr

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 30Air Receiver Relief Valve Figure 40: Air Receiver Relief Valve Air Receiver Relief Valve — To guard a

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 31Figure 42: Welder Power Units on extendable trays with latches The welding power units are secured to

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 32Air Compressor and tank 1. Check the compressor’s oil level through the sight gauge; add oil if requ

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 33engine to prevent the possibility of personal injury. 6. Check the engine oil level using the dipsti

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 34Winterfronts The genset enclosure can be fitted with Winter-fronts, contact Vanguard Equipment, Inc.

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 358. Close the Genset compartment doors and ensure the handle is securely latched. Note: Use caution w

S/N CA00600021 – UP (Weld-deck)ii WELDER DOGHOUSE ENCLOSURE ...

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 36Starting with Jump Start Cables Batteries give off flammable fumes that can explode resulting in pers

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 3715. Attempt to start the stalled engine. Refer to the Operation and Maintenance Manual, Engine Start

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 38AC Power-UP Notice Figure 52: Emergency Stop Push the RED emergency stop button to IMMEDIATELY trip t

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 39Ground Fault Circuit Interrupters (GFCI)—Test Daily To ensure that they are functioning properly, the

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 40Genset shutdown 1. Switch the Rated/Idle switch (1) to idle ( ). Allow the engine to idle 3

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 41Transportation Information Do not transport the machine with the walkways extended. Figure 56: Secure

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 42Figure 57: Shipping leg SHIPPING LEG 037-05-05-001AFigure 58: Forklift access037-05-05-113B12Figure 5

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 43Figure 60: Weld-deck shipping—distribute and secure the load 037-05-05-113A A BAB7 6 6776674. Evenly

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 44Torques for Standard Fasteners The following tables show general torques for bolts, and for nuts. The

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 45Torques for Vibration Isolator Mounts Note: The following tables show the required torque values for

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 1Foreword Literature Information This manual contains safety information, operation instructions, trans

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 46Recommended Service Intervals—Minimum Service Notice The procedures listed below are provided for qui

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 47Troubleshooting Notice This equipment is to be operated and serviced by qualified personnel only. Ref

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 48Engine Won’t Start Possible cause Solution 1 No fuel Fill fuel tank (carrier’s or pony). Refer to

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 49 Engine Shuts Down after 15 Seconds Possible cause Solution 1 Low oil level Check genset engine oi

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 50Engine Shuts Down after 30 Seconds Possible cause Solution 1 Low coolant level Check genset engin

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 51Engine Will Not Idle Possible cause Solution 1 Blown run/idle solenoid fuse. Note: Disconnect 24V

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 5224 VDC Electrical Faults Batteries fail to charge (low DC voltage) Possible cause Solution 1 Autom

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 5324VDC Alternator Overcharging (High DC voltage) Possible cause Solution 1 Batteries have failed.

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 54Main AC Power Electrical Faults No or Low 480 VAC Three Phase Supply Voltage Refer to the Operation a

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 5520A20A81234567 9101112 1513 14480V - 60Hz24VACSee P 2/2Note : LS1 contact is closed when inner door i

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 2California Proposition 65 Diesel engine exhaust and some of its constituents are known to the State of

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 5624VDC Controls Schematic 68PANEL LIGHT59OPTIONALSPARE FUSES1 7.552SS25049REMOTE STOPBAT SWFU47.510

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 57Compressor Faults Refer to the Operation and Maintenance Manual — Compressor for troubleshooting info

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 58Appendices: Equipment Modules’ Operation and Maintenance Manuals A) Air Compressor B) AC Generator

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 59Appendix A — Air CompressorThe following pages are taken from information published by the original e

OPERATION/MAINTENANCE MANUAL & PARTS LIST PL Series 2-Stage Pressure Lubricated Air Compressor & Units Featuring the PL70A Pump W

2 MAINTAIN COMPRESSOR RELIABILITY AND PERFORMANCE WITH GENUINE CHAMPION COMPRESSOR PARTS AND SUPPORT SERVICES Champion Compressor genuine parts, m

3 TABLE OF CONTENTS _______________________________________________________ Subject Page Maintain Compressor Reliability And Performance With ...

4 SAFETY AND OPERATION PRECAUTIONS ___________________________________________________________________________________ Because an air compressor is

5 EXPLANATION OF SAFETY INSTRUCTION SYMBOLS AND DECALS DANGER Indicates immediate hazards which will result in severe injury or death. WARNING I

6 INTRODUCTION ______________________________________________________________________ Champion PL Series compressors are the result of advanced engi

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 3Figure 2: Warning, high voltage electrocution hazard; located on main door control/distribution center

7 TWO STAGE AIR COMPRESSORS - MODEL PL70A DIMENSIONS ITEM PL70A A B C D E F G H J K L M N O P Q R Base-Width Bolt Down-Width (from cen

8 INSTALLATION WARNING Do not operate unit if damaged during shipping, handling or use. Operating unit if damaged may result in injury. 1. Perman

9 INSTALLATION (CONT’D) ELECTRICAL POWER SUPPLY It is essential that he power supply and the supply wiring are adequately sized and that the volt

10 ELECTRICAL POWER SUPPLY (CONT’D) Figure 1-2 Duplex Wiring Diagram CAUTION Wiring must be such that when viewing compressor from opposite sh

11 OPERATION This compressor has been inspected, thoroughly tested and approved at the factory. For this unit to give long satisfactory service it

12 GUIDE TO MAINTENANCE For Service contact an authorized Champion distributor. All requests should include model number and serial number. To ob

13 EVERY 90 DAYS OR 500 HOURS MAINTENANCE 1. Change crankcase oil and oil filter. Use only Champlub recip lubricant. 2. Check entire system for

14 GENERAL MAINTENANCE (Cont'd.) HYDRAULIC UNLOADER: This compressor is equipped with an unloading device operated by oil pressure. When the

15 COMPRESSOR PILOT VALVE PRESSURE ADJUSTMENT Proceed with the following instructions while compressor is running: 1. Loosen locknut (4) and back o

16 COMPRESSOR OIL SPECIFICATIONS Compressors are factory filled with CHAMPLUB hydrocarbon based recip lubricant. This is an ISO 100 non-detergent i

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 4Genset enclosure labels Figure 4: Warning, hot surface; located close to exhaust muffler (three places

17 TROUBLE SHOOTING CHART FOR COMPRESSOR WARNING Always disconnect unit from power supply and relieve all pressure from air tank before performing a

18 Troubleshooting Chart (cont’d) Symptom Possible Cause(s) Corrective Action Low or loss of oil pressure 1. Low crancase level. 2. Oil pickup

19 UNIT REPAIR PARTS ILLUSTRATION MODELS: HPL20-12, HPL20-25, HPL25-12, HPL25-25, HPL30-12, & HPL30-25 REPAIR PARTS LIST MODEL HPL20

20 UNIT REPAIR PARTS ILLUSTRATION MODELS: BPL-20, BPL-25, & BPL-30 REPAIR PARTS LIST MODEL BPL-20 BPL-25 BPL-30 1 Pump PL70A

21 UNIT REPAIR PARTS ILLUSTRATION MODELS: HPL20D-25, HPL25D-25, & HPL30D-25 REPAIR PARTS LIST MODEL HPL20D-25 HPL25D-25 HPL30D-25 1

22 COMPRESSOR REPAIR PARTS ILLUSTRATION Models: PL70A 2827252321262422201716151498763452930313233343537363718191021393840415413454212124245254311

23 Repair Parts List Compressor Model PL70A Ref. No. Description Part Number Qty. 1 Crankcase P07393D 1 2 Pipe plug 64AA5 1 3 Oil level gauge

24 Repair Parts List Compressor Model PL70A Ref. No. Description Part Number Qty. 51 High pressure piston with pin ZM1393 2 52

25 COMPRESSOR REPAIR PARTS ILLUSTRATION Model: PL70A Repair Parts List Models PL70A Ref. No. Description Part Number Qty. 1 1/4 x 1/8" NP

26 UNIT HAZARD DECAL LISTING PAGE DESCRIPTION PART NO. 27 PRODUCT LIABILITY DECAL SHEET - MASTER P10157A Unit Pressure Setting 1 N

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 5 Figure 6: Warning, Jump Start; located on the service panel—genest enclosure. Figure 7: Warning, imp

27 UNIT HAZARD DECALS

28 PUMP HAZARD DECALS F

29 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY ● CLEAN FILTER ● CLEAN COMPRESSOR ● CHECK V-BELTS MONTHLY

30 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY ● CLEAN FILTER ● CLEAN COMPRESSOR ● CHECK V-BELTS MONTHLY

31 RECORD OF MAINTENANCE SERVICE DAILY ● CHECK OIL LEVEL ● DRAIN MOISTURE FROM TANK WEEKLY ● CLEAN FILTER ● CLEAN COMPRESSOR ● CHECK V-BELTS MONTHLY

32 www.championpneumatic.com Champion 1301 North Euclid Avenue Princeton, Illinois 61356 USA Phone (815) 875-3321 Fax (815) 872-0421 E-mail:

037-08OP-001B S/N CA00600021 – UP (Weld-deck) 92Appendix B — AC Generator and Voltage Regulator The following pages are taken from information publis

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