Eff w/serial No. LC Thru LJ003064

Transcription

1 TM-448L Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Engine Driven Welder/Generator Big Blue 500D Big Blue 600 X (Deutz-Powered) Eff w/serial LC58564 Thru LJ File: Engine Drive Visit our website at

2 SECTION 14 PARTS LIST EFF W/SERIAL NO. LC58564 THRU LJ Hardware is common and not available unless listed. A Deutz F4L011 engine-powered unit is shown below. See insert for parts specific to a Deutz F3L91-powered unit. s not related to the engines are the same in both units (Fig. 15-7) (FIG. 15- OR 15-3) (CC ONLY) (CC ONLY) (CC ONLY) 104 (FIG OR 15-5) CC CV CC Models Only CC/CV Models Only Figure Main Assembly TM-448 Page 130

3 Eff w/serial LC58564 Thru LJ A Deutz F4L011 engine-powered unit is shown below. See insert for parts specific to a Deutz F3L91-powered unit. s not related to the engines are the same in both units Deutz F3L91 Engine (Fig. 15 6) (Fig. 15-6) / TM-448 Page 131

4 Eff w/serial LC58564 Thru LJ Figure Main Assembly Panel, Gen Lh Panel, Gen Lh Ss Label, Warning Moving s (Prior to LF310974) Label, Warning Moving s Can Cause Injury (Eff w/lf310974) Panel, Engine Side Panel, Engine Side Ss Baffle, Engine Side (Export Models) Z Reactor, Ac Z Reactor, Ac Environmental T Block, Term 30a 4 Pole Frict Term Str Link, Jumper Term Blk 30a Bracket, Mtg Strip Terminal Brace, Front To Center Upright Label, Caution Do Not Use Ether SR4, SR Rectifier, Integ Bridge 40. Amp 800v CB Circuit Breaker, Auto Reset 4vdc 7 Amp Pan, Reactor And Rectifier T Transformer W/Bracket T Transformer W/Bracket (Environmental Coating) Extrusion, Rubber Clamp/Bulb (Order By Ft)... 3ft Firewall, Top Cover, Plate Hose, Air Cleaner Bracket, Mtg Air Cleaner Air Cleaner, Intake * Filter, Air Element Primary * Filter, Air Element Safety Seal, Weather Lift Eye Hose, Sae.31 Id X.560 Od X (Order By Ft) Upright, Center Assembly Base Base E-Coat Bracket, Hold Down Fuel Tank Rear Bracket, Mtg Nyl 1/ Conduit Cover, Top Cover, Top Ss Grommet, Plastic Neck Filler Fuel Cap, Tank Screw-On In W/Vent Label, Use Diesel Fuel Only (Wordless Label) (Prior to LF310974) Label, Use Diesel Fuel Only (Wordless Label) (Eff w/lf310974) Label, Warning Falling Equipment (Wordless Label) (Prior to LF310974) Label, Warning Falling Equipment Can Cause Serious (Eff w/lf310974) Label, Warning Hot Exhaust (Prior to LF310974) Label, Warning Hot Exhaust s Do Not Touch (Eff w/lf310974) Pipe, Muffler Extension Elbow Od Pipe, Exhaust Cover, Radiator Access Support, Cover Support, Cover E-Coat Clamp, Muffler.000 Dia U Pld Manifold, Exhaust Muffler Figure Generator Guard, Starter (Deutz F4L011 engine) Bracket, Mtg Engine Lh (Deutz F4L011 engine) Edge Trim, Style Tl750-B X 1/16 Black W/Clips Baffle, Air (Deutz F4L011 engine)... 1 TM-448 Page 13

5 Eff w/serial LC58564 Thru LJ Figure Main Assembly (Continued) Engine, Deutz Dsl Elec F4L011 (consisting of) * Filter, Oil (Engine) (Deutz F4L011 engine) * Filter, Fuel Spin-On (Deutz F4L011 engine) * Filter, Fuel Secondary (Deutz F4L011 engine) * Switch, Oil Pressure * Sender, Coolant Idle, Solenoid Assy Bracket, Support Solenoid * Belt, Blower (Deutz F4L011 engine) Box, Air Intake (Deutz F4L011 engine) Upright, Rear Upright, Rear Ss Cable, Bat Neg 4 In Lg Awg W/Clamp And.375rng Terminal Protector, Battery Post Mtg Cable, Bat Pos 45 In Lg 1 Awg W/Clamp And.406rng Bracket, Battery Holddown Battery, Stor 1v 650crk 110rsv Gp Bolt, J Stl X Pld Cover, Battery Access Cover, Battery Access Ss Label, Warning Battery Explosion Can Blind (Prior to LF310974) Label, Warning Battery Explosion Can Blind (Eff w/lf310974) Guard, Belt Screw, X 4.00hexhd Pln Gr 5 Pld Washer, Flat.656 Id X.50 Od X.187t Stl Pld Bracket, Mtg Engine Rh (Deutz F4L011 engine) Retainer, Mount Eng/Gen Tubing, Stl.875 Od X 1ga Wall X Mount, Eng/Gen Nprn.875 Id X.500 Od X Nut, hex.76h Stl Pld Elastic Stop Nut Hose, Oil Drain Assy 0 In (Consisting Of) Valve, Oil Drain 3/8-18nptf Fitting, Hose Brs Barbed Fem 1/tbg X 3/8npt Hose, Sae.500 Id X.780 Od Xc Oil (Order By Ft)... ft Fitting, Hose Brs Barbed Elbow Fem 1/ Tbg X 1/ Npt Fitting, Adapter Oil Drain Washer, Oil Drain (Available Through Engine Manufacturer) Bracket, Mtg Solenoid (Deutz F4L011 engine) Base, Fuel Filter Assy Fitting, Hose Brs Barbed Elbow M 5/16tbg X 1/4npt Hose, Sae.31 Id X.560 Od X Hose, Sae.31 Id X.560 Od X * Filter, Fuel Spin-On Keeper, Latch Engine Access Door Channel, Stiffener Engine Access Channel, Stiffener Engine Access E-Coat Latch, Paddle Series 0 (Black) Label, Diesel Engine Maintenance Deutz (Wordless Label) Door, Engine Access Door, Engine Access Ss Hinge, Door Access 180deg Stop, Door Panel, Rocker Panel, Rocker Ss Panel, Gen Rh Panel, Gen Rh Ss... 1 TM-448 Page 133

6 Eff w/serial LC58564 Thru LJ Figure Main Assembly (Continued) Bumper, Door Engine Access Tank, Fuel (Consisting Of) Bushing, Tank Fuel Clamp, Hose clp Dia Slfttng Fitting, Stl Barbed Elbow W/.047 In Orf Zinc Pld Fitting, Stand Pipe Hose.50 X 9.60 Lg 90deg Zinc Fitting, Stl Barbed Elbow Zinc Pld Sender, Fuel Gauge Deep Tank Fitting, Stand Pipe Hose.315 X 9.60 Lg 90deg Zinc Valve, Drain Fuel 180deg Bushing, Tank Fuel Extrusion, Rubber W/Adhesive X D (Order By Ft)... 6ft Bracket, Mtg Unit Bracket, Hold Down Fuel Tank Label, Warning Do Not Weld On Base (Prior to LF310974) Label, Warning Do Not Weld On Base (Eff w/lf310974) Panel, Mtg Components R4... C C Resistor, Ww Fxd 375w 50 Ohm W/Mtg Bkt R Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt R3... C C Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt Figure 15-, Figure 15-3 Control Box Assembly Firewall, Lower Figure Main Rectifier Assembly Top, Cover Front Upright Top, Cover Front Upright Ss Upright, Front Upright, Front Ss Label, Warning General Precautionary (Prior to LF310974) Label, Warning General Precautionary (Eff w/lf thru LH017115) Label, Warning General Precautionary (Eff w/lh017115) Figure 15-4, Figure 15-5 PANEL, front w/components Xfmr, Current Sensing C V Bracket, Mtg Box Fcr PC1.. C V Module, Field Current Regulator Nut,.50-0 U-Nut Multi-Thread Nut, U-Nut Multi-Thread... 3 Prior to LF310974: Kit, Label (Includes Safety And Informational Labels) Kit, Label (Includes Safety And Informational Labels) (Wordless Labels) 1 Eff w/lf310974: Kit, Label (Includes Safety & Informational Labels) (CC models) Kit, Label (Includes Safety & Informational Labels) (CC/CV models) Kit, Label (Includes Safety & Informational Labels) (CC export models)... (Deutz F4L011 engine) Kit, Label (Includes Safety & Informational Labels) (CC/CV export models)... (Deutz F4L011 engine) Kit, Label (Includes Safety & Informational Labels) (CC export models)... (Deutz F3L91 engine) Kit, Label (Includes Safety & Informational Labels) (CC/CV export models)... (Deutz F3L91 engine) Engine, Deutz Dsl Elec F3l91 D / * Filter, Oil (Deutz F3L91 engine) * Belt, Blower (Deutz F3L91 engine) * Switch, Pressure Oil 1.5 Bar Nc Cont * Sender, Coolant Temp & 130 Degee C Switch Backplate, Deutz F3L91 engine Support, Front Engine (Deutz F3L91 engine) FS Shutdown Kit, Engine (Deutz F3L91 engine)... 1 TM-448 Page 134

7 Eff w/serial LC58564 Thru LJ Figure Main Assembly (Continued) Ftg, Adapter Oil Drain (Deutz F3L91 engine) Manifold, Exhaust Muffler (Deutz F3L91 engine) Baffle, Lower Air Outlet (Deutz F3L91 engine) Baffle, Upper Air Outlet (Deutz F3L91 engine) Baffle, Air Intake (Deutz F3L91 engine) Hose, Air Cleaner (Deutz F3L91 engine) Box, Air Intake (Deutz F3L91 engine) Guard, Starter Hole (Deutz F3L91 engine) Washer, Flat 6.5idx11.50odx.06t Buna N Label, Stick Overlap Weld Ranges Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit) (Eff w/lh017115) 1 + When ordering a component originally displaying a precautionary label, the label should also be ordered. * Recommended Spare s. optional C C CC models only. C V CC/CV models only. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor C Figure 15-. Control Box Assembly CC Models TM-448 Page 135

8 Eff w/serial LC58564 Thru LJ Figure 15-. Control Box Assembly CC Models (Figure ) F1, F.. * Fuse, Mintr Cer Slo-Blo 10a 50v Holder, Fuse Mintr.50 X Control Box, Lh Control Box, Rh Cover, Control Box C Capacitor, Polyp Met Film 10. Uf 50 Vac 10% Harness, Control Box, Weld Control (Consisting Of) CR Relay, Ocv Control D8/C Diode/Capacitor Board SR1, SR Rectifier, Integ 40a 800v CR Relay, Encl 1vdc Spst 30a/15vdc (Prior to LF310974) CR Relay, Encl 1vdc Dpst No 5a 6pin Flange (Eff w/lf310974) S Switch, Tgl Spdt 15a 15vac On None On Spd Term Chr... (Located On Front Panel, See Figure 15-4) S Switch, Tgl 3pdt 15a 15vac On None On Spd Term... (Located On Front Panel, See Figure 15-4) RC Connector, Rect Univ p/S 3 Row Rcpt Cable/Panel Lkg RC Connector, Rect Univ 084 1p/S 3 Row Rcpt Cable/Panel Lkg RC Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg Socket, Relay 5 Pin Conn, Body 5 Terminal (To Engine Control Switch S1) Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Conn, Rect Univ 084 3p/S 1row Plug Cable Lkg CB11, 1, Supplementary Protector, Man Reset 1p 15a 50vac Harness, Unit Weld Control (Consisting Of) PLG Conn, Rect Univ 084 1p/S 3row Plug Cable Lkg Seal, Wire Univ 1p/S 3row PLG Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg Clip, Snap In.630 Bundle.50 Hole.48 Thk Clamp, Capacitor 1.375dia C Capacitor, Elctlt 40uf 00vdc R Resistor, Ww Fxd 30 W 5 Ohm Faston Te PC Module, Pull To Idle, Two Output, 7 Pin CR Relay, Encl 1vdc Dpdt 0a/10vac 8pin Flange Mtg CR Relay, Encl 1vdc Spst 30a/15vdc 5pin Flange Mtg CR Relay, Encl 1vdc Spst 30a/15vdc Spin Flange Mtg Harness, Engine Control (Deutz F4L011 engine) (consisting of) D1/C Diode/Capacitor Board CB Circuit Breaker, Auto Reset 1vdc 40a Socket, Relay 5 Pin PLG Connector, Rect Univ p/S 3 Row Plug Cable Lkg Housing, Contact 10-Pole CR Relay, Encl 6vdc Spst 35a/14vdc 5 Pin CB Circuit Breaker, Auto Reset 1vdc 1 Amp Harness, Engine Control (Deutz F3L91 engine) (consisting of) D8/C Diode/Capacitor Board CB Circuit Breaker, Auto Reset 1vdc 40a Socket, Relay 5 Pin PLG Connector, Rect Univ p/S 3 Row Plug Cable Lkg CR Relay, Encl 6vdc Spst 35a/14vdc 5 Pin CB Circuit Breaker, Auto Reset 1vdc 1 Amp CR Relay, Encl 1vdc Spst 70a 4pin Flange Mtg TD Timer, Delay On Make/Break Open 30 Sec 1vdc CR Relay, Encl 1vdc Spst 30a/15vdc 5pin Flange Mtg (Eff w/lh04758) Harness, Fuel Shutdown Solenoid (Consisting Of) (Eff w/lh04758) R Resistor, Hsc 30 W 3 Ohm (Eff w/lh04758) Socket, Relay 5 Pin (Eff w/lh04758)... 1 Optional *Recommended Spare s. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 136

9 Eff w/serial LC58564 Thru LJ C Figure Control Box Assembly CC/CV Models Figure Control Box Assembly CC/CV Models (Figure ) F1, F.. * Fuse, Mintr Cer Slo-Blo 10a 50v Holder, Fuse Mintr.50 X Control Box, Lh Control Box, Rh CR Relay, Encl 1vdc Spst 30a/15vdc Spin Flange Mtg CR Relay, Encl 1vdc Spst 70a 4pin Flange Mtg CR Relay, Encl 6vdc Spst 35a/14vdc 5 Pin CR Relay, Encl 1vdc Spst 30a/15vdc 5pin Flange Mtg D8/C Diode/Capacitor Board CB Circuit Breaker, Auto Reset 1vdc 1 Amp CB Circuit Breaker, Auto Reset 1vdc 40a CR Relay, Encl 1vdc Spst 30a/15vdc (Prior to LF310974) CR Relay, Encl 1vdc Dpst No 5a 6pin Flange (Eff w/lf310974) PC Module, Pull To Idle, Two Output, 7 Pin SR Rectifier, Integ 40a 800v Cover, Control Box CR Relay, Encl 1vdc Dpdt 0a/10vac 8pin Flange Mtg PC Circuit Card Assy, Display Stand-Off, Support Pc Card TD Timer, Delay On Make/Break Open 30 Sec 1vdc C Capacitor, Elctlt 40uf 00vdc Clamp, Capacitor 1.375dia D1/C Diode Capacitor Board... 1 TM-448 Page 137

10 Eff w/serial LC58564 Thru LJ Figure Control Box Assembly CC/CV Models (Continued) CB11, 1, Supplementary Protector, Man Reset 1p 15a 50vac CR Relay, Encl 1vdc Spst 30a/15vdc 5pin Flange Mtg (Eff w/lh04758) Harness, Fuel Shutdown Solenoid (Consisting Of) (Eff w/lh04758) R Resistor, Hsc 30 W 3 Ohm (Eff w/lh04758) Socket, Relay 5 Pin (Eff w/lh04758) Harness, Control Box, Cv Weld Control (Consisting Of) RC Connector, Rect Univ p/S 3 Row Rcpt Cable/Panel Lkg RC Connector, Rect Univ 084 1p/S 3 Row Rcpt Cable/Panel Lkg RC Connector, Rect Univ 084 9p/S 3 Row Rcpt Cable/Panel Lkg Socket, Relay 5 Pin S Switch, Rotary 6 Position Gold Contacts... (Located On Front Panel, See Figure 15-5) S Switch,Tgl Spdt 15a 15vac On None On Spd Term Chr... (Located On Front Panel, See Figure 15-5) Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Conn, Body 5 Terminal (To Engine Control Switch S1) Conn, Rect Cinch 18 Pin Plug, Cavity 18,30 Position Cinch Connector Seal, Switch 6 Position Rotary.50 Shaft Conn, Rect Metrmate 10skt 1row Plug Cable Lkg Harness, Engine Control (Deutz F4l011 Engine) (Consisting Of) Socket, Relay 5 Pin PLG Connector, Rect Univ p/S 3 Row Plug Cable Lkg Housing, Contact 10-Pole Harness, Engine Control (Deutz F3l91 Engine) (Consisting Of) Socket, Relay 5 Pin PLG Connector, Rect Univ p/S 3 Row Plug Cable Lkg Seal, Wire Univ 15p/S 3 Row... 1 Optional *Recommended Spare s. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 138

11 Eff w/serial LC58564 Thru LJ Hardware is common and not available unless listed Figure Panel, Front w/components CC Models Figure Panel, Front w/components CC Models (Figure ) Plate Screened, Ident Control Rating; When Ordering This,... The Nameplate Should Also Be Ordered) Nameplate, Screened (Order By Model And Serial Number) Panel, Engine/Weld Control Panel, Engine/Weld Control Ss S Switch, Range/Changeover... 1 TM-448 Page 139

12 Eff w/serial LC58564 Thru LJ Figure Panel, Front w/components CC Models (Continued) Harness, Range (Consisting Of) RC Housing, Rect Univ 084 4p/S 1 Row Rcpt R Rheostat, Ww 300w 34 Ohm Spacer, Nylon S Switch, Tgl Dpdt 15a 15vac (Included In Control Box Harness,... See Figure 15-) S Switch, Tgl Spdt 15a 15vac On-None-On Spd Term Chr (Included In... Control Box Harness, See Figure 15-) RC Receptacle, Twlk Grd p3w 15a 15v S Switch, Tgl Spst 3a 50v Off None (On) Spd Term S Switch, Ignition 4 Position W/Handle Clip, Circuit Breaker Retaining CB Supplementary Protector, Man Reset p 0a 50vac (European Receptacle) CB Supplementary Protector, Man Reset p 40a 40vac (Export Models) Guard, Circuit Breaker CB, CB Supplementary Protector, Man Reset p 0a 50vac Harness, Generator Power (Consisting Of) CB Supplementary Pro, Man Reset 1p 0a 50vac Frict GFCI Receptacle, Str Dx Grd p3w 15/0a 15v Gfci RC Receptacle, Tw Lk Grd p3w 30a 50v L6-30r Harness, Generator Power (European Receptacle) (Consisting Of) CB Supplementary Pro, Man Reset 1p 0a 50vac Frict CB Supplementary Protector, Man Reset 1p 15a 50vac GFCI Receptacle, Str Dx Grd p3w 15/0a 15v Gfci Harness, Generator Power (Export Models) Block, Term Assy Standard Link, Jumper Term Block RC Receptacle, Str p3w 16a 0v Flange Mtg (European Receptacle) RC Receptacle, Str p3w 3a 130v Flange Mtg (Export Models) RC Receptacle, Str p3w 16a 0v Flange Mtg (Export Models) RC Receptacle, Str p3w 16a 130v Flange Mtg (Export Models) Label, Warning, Electric Shock And Moving s Etc Panel, Gen Pwr Panel, Gen Pwr Ss Panel, Gen Pwr (European Receptacle) Panel, Gen Pwr (110/0 Volt Receptacles) (Export Models) Stud, Brs.50 0 X W/Hex Collar Nut, hex.19h Brs Label, Do Not Switch While Welding S Switch, Polarity S Switch, Ac/Polarity Panel, Mtg Terminal Pwr Output Panel, Mtg Terminal Pwr Output Ss Terminal, Pwr Output Black Washer, Output Stud Spacer, Output Stud Boot, Generic Output Stud Handle, Switch Pin, Spring Cs.156 X Terminal, Pwr Output Red Cover, Receptacle W/Gasket Boot, Circuit Breaker Clear Hex Nut Boot, Toggle Switch Lever Cover, Receptacle Twistlock Meter, Volt Dc 8 18 Scale.50 In Black Face FUEL Gauge, Fuel Elec Switch W/O Sensor... 1 TM-448 Page 140

13 Eff w/serial LC58564 Thru LJ Figure Panel, Front w/components CC Models (Continued) HM Meter, Hour 1-4vdc.5dia TEMP Gauge, Coolant Temp Deg F Sender, Coolant Temp 300 Deg F M16 X OIL Gauge, Pressure Oil Psi Sender, Pressure Oil Psi Adapter, Oil Pressure Sender (Deutz F4L011) V Volt Meter, W/Leads A Ammeter, W/Leads Handle, Switch Range Pin, Spring Cs.156 X Knob, Pointer Blank, Snap In Nyl.750 Mtg Hole Black... 1 Optional + When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-448 Page 141

14 Eff w/serial LC58564 Thru LJ Hardware is common and not available unless listed Figure Panel, Front w/components CC/CV Models Figure Panel, Front w/components CC/CV Models (Figure ) Plate Screened, Ident Control; When Ordering This,... The Nameplate Should Also Be Ordered) Nameplate, Screened (Order By Model And Serial Number) Panel, Engine/Weld Control Panel, Engine/Weld Control Ss S Switch, Range/Changeover Harness, Range (Consisting Of) RC Housing, Rect Univ 084 4p/S 1 Row Rcpt R Pot, Cp Flat 1t w 1k Ohm Linear... 1 TM-448 Page 14

15 Eff w/serial LC58564 Thru LJ Figure Panel, Front w/components CC/CV Models (Continued) S Switch, Rotary 6 Position Gold Contacts (Included In Control Box Harness,... See Figure 15-3) Guard, Circuit Breaker (For S6 Not Included W/Harness) S Switch, Tgl Spdt 15a 15vac On-None-On Spd Term Chr (Included In... Control Box Harness, See Figure 15-3) Spacer, Nylon PC Circuit Card Assy, Connector/Receptacle CB Supplementary Protector, Man Reset 1p 15a 50vac CB Supplementary Pro, Man Reset 1p 10a 50vac Frict S Switch, Tgl Spst 3a 50v Off None (On) Spd Term S Switch, Ignition 4 Position W/Handle Clip, Circuit Breaker Retaining CB Supplementary Protector, Man Reset p 0a 50vac CB Supplementary Protector, Man Reset p 40a 40vac Guard, Circuit Breaker CB, CB Supplementary Protector, Man Reset p 0a 50vac Harness, Generator Power (Consisting Of) CB Supplementary Pro, Man Reset 1p 0a 50vac Frict GFCI Receptacle, Str Dx Grd p3w 15/0a 15v Gfci RC Receptacle, Tw Lk Grd p3w 30a 50v L6-30r Harness, Generator Power (European Receptacle) (Consisting Of) CB Supplementary Pro, Man Reset 1p 0a 50vac Frict CB Supplementary Protector, Man Reset 1p 15a 50vac GFCI Receptacle, Str Dx Grd p3w 15/0a 15v Gfci Harness, Generator Power (Export Models) Block, Term Assy Standard Link, Jumper Term Block RC Receptacle, Str p3w 16a 0v Flange Mtg (European Receptacle) RC Receptacle, Str p3w 3a 130v Flange Mtg (Export Models) RC Receptacle, Str p3w 16a 0v Flange Mtg (Export Models) RC Receptacle, Str p3w 16a 130v Flange Mtg (Export Models) RC Rcpt, Str 3p4w 50a 15/50v Stand-Off, Insul.50-0 X Connector, Clamp Cable Guard, Circuit Breaker Terminal, Ring Tng Screw Clamp CB Supplementary Protector, Man Reset 3p 50a 50vac Panel, Generator Power Panel, Gen Pwr Ss Panel, Gen Pwr (European Receptacle) Panel, Gen Pwr (110/0 Volt Receptacles) (Export Models) Panel, Generator Power (Full Kva Option) Boot, Circuit Breaker 3 Pole Plug, Protective Bushing, Conduit 1 In Nut, hex.19h Brs Cover, Receptacle W/Gasket Stud, Brs.50 0 X W/Hex Collar CT Transformer, Current Sensing Label, Warning, Electric Shock And Moving s Etc Label, Warning 3 Ph Generator Power Cover, Receptacle.50 Dia Lexan Boot, Circuit Breaker Clear Hex Nut S Switch, Polarity S Switch, Ac/Polarity Panel, Mtg Terminal Pwr Output... 1 TM-448 Page 143

16 Eff w/serial LC58564 Thru LJ Figure Panel, Front w/components CC/CV Models (Continued) PC4, PC Circuit Card Assembly, Filter Hf Terminal, Pwr Output Black Washer, Output Stud Stand-Off, Support Spacer, Output Stud Boot, Generic Output Stud Handle, Switch Pin, Spring Cs.156 X Terminal, Pwr Output Red Label, Do Not Switch While Welding Boot, Toggle Switch Lever Boot, Circuit Breaker Clear Hex Nut Conn, Circ Ms Protective Cap Size HM Meter, Hour 1-4vdc.5dia FUEL Gauge, Fuel Elec Switch W/O Sensor Meter, Volt Dc 8 18 Scale.50 In Black Face TEMP Gauge, Coolant Temp Deg F Sender, Coolant Temp 300 Deg F M16 X OIL Gauge, Pressure Oil Psi Sender, Pressure Oil Psi Adapter, Oil Pressure Sender (Deutz F4L011) A Ammeter, W/Leads V Volt Meter, W/Leads Knob, Pointer.875 Dia X.50 Id W/Set Screws Plstc Handle, Switch Range Pin, Spring Cs.156 X Knob, Pointer.375 Dia X.50 Id Harness, Unit Weld Control Cv (Consisting Of) PLG Connector, Rect Univ 084 4p/S 1 Row Plug Cable Lkg PLG Connector, Rect Cinch 30 Pin PLG Connector, Rect Univ p/S Row Plug Cable PLG Connector, Rect Univ 084 1p/S 3 Row Plug Cable Bushing, Snap-In Nyl.375 Id X.500 Mtg Hole Clip, Conduit Convoluted 1/ In Mtg Hole Seal, Wire Univ 1p/S 3 Row Blank, Snap-In Nyl.750 Mtg Hole Blk Blank, Snap In Nyl.50 Mtg Hole Black... Optional + When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 144

17 Eff w/serial LC58564 Thru LJ Hardware is common and not available unless listed C Figure Generator Figure Generator (Figure ) Screw, X 1.50hexhd Pln Gr 5pld Washer, Conical Spring.406 Id X.875 Od Pltd Endbell, Gen (Consisting Of) O-Ring,.859 Id X.139cs Stator, Exciter/Gen Pwr Stator, Exciter/Gen Pwr (Export Models) Stator, Weld Assembly Complete Stator, Weld Assembly Complete (Full Kva Option) Label, Warning Moving s Can Cause Injury Guard, Generator Wire Mesh Spring, Ext.40 Od X.041 Wire X 3.500pld Baffle, Air ROTOR Rotor, Generator Segmented Assy (Includes) Rotor, Generator (Includes) Ring, Rtng Ext Shaft X.050 Thk Bearing, Ball Rdl Sgl Row X.830 X Hub, Drive (Not Sold Separately) Fan, Rotor Assy Generator (Segmented) (Includes) Plate, Flex Hubmount Fan, Rotor Segmented Assy Gen Screw, M10 1.5x 5 Hex Hd Pln 8.8 Pln Washer, Lock.40idx0.709odx.087t Stl Split10mm Screw, 31 18x1.00 Hexwhd.66d Stl Pld Slffmg Tap Rw Washer, Lock.40idx0.709odx.087t Stl Split10mm... 4 TM-448 Page 145

18 Eff w/serial LC58564 Thru LJ Figure Generator (Continued) Screw, M10 1.5x 5 Hex Hd Pln 8.8 Pln Cover, Starter Hole Perkins/Continental Washer, Lock.40idx0.709odx.087t Stl Split10mm Screw, M X 50hexhd Pln 8.8pld Screw,.31 18x.75 Hexwhd.66d Stl Pld Slffmg Tap Rw Screw, X.5hexhd Pln Gr 5pld Washer, Lock.318 Id X Washer, Exciter * Brush, Contact Clip, Spring Brushholder Assembly, Gen Washer, Flat.375idx0.875odx.083t Stl Pld Washer, Lock.318idx0.586odx.078t Stl Pld Split Screw,.31 18x1.5 Hex Hd Pln Gr5 Pld Harness, Brush (Consisting Of) PLG Connector, (Kit) Rect Univ 084 9p/S 3 Row Plug Cable Lkg Seal, Wire Univ 9p/S 3 Row When ordering a component originally displaying a precautionary label, the label should also be ordered. *Recommended Spare s. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. Notes TM-448 Page 146

19 Eff w/serial LC58564 Thru LJ Hardware is common and not available unless listed A Figure Main Rectifier Assembly Figure Main Rectifier Assembly (Figure )... SR Rectifier (Consisting Of) (Prior to LH00538) SR Rectifier, Environmental (Consisting Of) (Eff w/lh00538) Connection Board, Rectifier Ac Bus Bar, Connection Board Enclosure, Rectifier Stand-Off, Support PC Circuit Card Assembly, Protection Insulator, Heat Sink Heat Sink, Rectifier Al D3, D5, D Diode, Rect 75a 300v Sp (Prior to LH00538) D3, D5, D Diode, Rect 75a 300v Sp (Eff w/lh00538) D, D4, D Diode, Rect 75a 300v Rp (Prior to LH00538) D, D4, D Diode, Rect 75a 300v Rp (Eff w/lh00538)... 3 To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 147

20 Notes Eff w/serial LC58564 Thru LJ Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. TM-448 Page 148

21 TM-448L Processes Stick (SMAW) Welding TIG (GTAW) Welding MIG (GMAW) Welding Flux Cored (FCAW) Welding Air Carbon Arc (CAC-A) Cutting and Gouging Engine Driven Welder/Generator Big Blue 500D Big Blue 600 X (Deutz-Powered) Eff w/serial LJ Thru MG06006E File: Engine Drive Visit our website at

22 SECTION 15 PARTS LIST EFF W/SERIAL NO. LJ THRU MG06006E Hardware is common and not available unless listed. A Deutz 011 engine-powered unit is shown below. See insert for parts specific to a Deutz 91-powered unit. s not related to the engines are the same in both units (CV Only) (CV Only) 91 (Figure 15-11) (Figure 15- or 15-3) 86 (CC Only) (CC Only) (CC Only) 96 (Figure 15-6, 15-7, 15-8, or 15-9) 95 (Figure 15-4 or 15-5) CC CV CC Models Only CC/CV Models Only Figure Main Assembly TM-448 Page 150

23 Eff w/serial LJ Thru MG06006E A Deutz 011 enginepowered unit is shown below. See insert for parts specific to a Deutz 91-powered unit. s not related to the engines are the same in both units Deutz 91 Engine (Fig ) (Fig ) / TM-448 Page 151

24 Eff w/serial LJ Thru MG06006E Figure Main Assembly Panel, Gen Lh Panel, Gen Lh Ss Label, Warning Moving s Can Cause Injury (Prior to MF51004E) Label, Warning Moving s (En/Fr Sym) (Eff w/mf51004e) Panel, Engine Side (Prior to ME510133E) Panel, Engine Side (Eff w/me510133e) Panel, Engine Side Ss Baffle, Engine Side (Export Models) Z Reactor, AC Z Reactor, AC Environmental T Block, Term 30A 4 Pole Frict Term Str Link, Jumper Term Blk 30A Bracket, Mtg Strip Terminal Brace, Front To Center Upright Label, Caution Do Not Use Ether (Prior to MF51004E) Label, Notice Do Not Use Ether (En/Fr Sym) (Eff w/mf51004e) SR4, SR Rectifier, Integ Bridge 40. Amp 800V CB Circuit Breaker, Auto Reset 4VDC 7 Amp Pan, Reactor And Rectifier T Transformer W/Bracket T Transformer W/Bracket (Environmental Coating) Extrusion, Rubber Clamp/Bulb (Order By Ft)... 3ft Firewall, Top Cover, Plate Hose, Air Cleaner Bracket, Mtg Air Cleaner Air Cleaner, Intake * Filter, Air Element Primary * Filter, Air Element Safety Seal, Weather Lift Eye Hose, Sae.31 Id X.560 Od X (Order By Ft) Upright, Center Assembly Base Base E-Coat Bracket, Hold Down Fuel Tank Rear Bracket, Mtg Nyl 1/ Conduit Cover, Top (Prior to MD44004E) Cover, Top (Eff w/md44004e) Cover, Top Ss Grommet, Plastic Neck Filler Fuel Cap, Tank Screw-On In W/Vent W/Lanyard 8in Label, Use Diesel Fuel Only (Wordless Label) (Prior to MF51004E) Label, Use Diesel Fuel Only (En/Fr Sym) (Eff w/mf51004e) Label, Warning Falling Equipment Can Cause Serious (Prior to MF51004E) Label, Warning Falling Equipment (En/Fr Sym) (Eff w/mf51004e) Label, Warning Hot Exhaust s Do Not Touch (Prior to ME50019E) Label, Warning Hot s (Eff w/me50019e Thru MF510041E) Label, Warning Hot s (En/Fr Sym) (Eff w/mf51004e) Pipe, Muffler Extension Elbow Od Pipe, Exhaust Cover, Radiator Access (Prior to MD44004E) Cover, Radiator Access (Eff w/md44004e) Support, Cover Support, Cover E-Coat Clamp, Muffler.000 Dia U Pld Manifold, Exhaust Muffler ( of engine eff w/lj004970) Figure Generator... 1 TM-448 Page 15

25 Eff w/serial LJ Thru MG06006E Figure Main Assembly (Continued) Guard, Starter (Deutz 011 Engines) Bracket, Mtg Engine Lh (Deutz 011 Engines) Edge Trim, Style Tl750-B X 1/16 Black W/Clips 1.65 (Prior to LJ004970) Baffle, Air (Deutz 011 Engines) Engine, Deutz Dsl Elec F4L011 (Prior to LJ004970) (consisting of) Engine, Deutz Dsl Elec D011L04i... (Eff w/lj thru MB110095E) (consisting of) Engine, Deutz Dsl Elec D011L04i (Eff w/mb110096e) (consisting of) * Filter, Oil (Engine) (Deutz 011 Engines) * Filter, Fuel Spin-On (Deutz 011 Engines) * Filter, Fuel Secondary (Deutz 011 Engines) * Switch, Oil Pressure * Sender, Coolant Filter Kit, Deutz (011) Idle, Solenoid Assy * Belt, Blower (Deutz 011 Engines) Box, Air Intake (Deutz 011 Engines) Upright, Rear Upright, Rear Ss Cable, Bat Neg 4 In Lg Awg W/Clamp And.375rng Cable, Bat Pos 45 In Lg 1 Awg W/Clamp And.406rng Bracket, Battery Holddown (Prior to ME0069E) Bracket, Battery Holddown (Eff w/me0069e) Battery, Stor 1v 650crk 110rsv Gp Bracket, Battery Locator Adj (Eff w/me0069e) Bolt, J Stl X Pld Spacer, Stl.33 Id X.65 Od X.141 Thk (Eff w/me0069e) Cover, Battery Access Cover, Battery Access Ss Label, Warning Battery Explosion Can Blind (Prior to MF51004E) Label, Warning Battery Explosion (En/Fr Sym) (Eff w/mf51004e) Guard, Belt Screw, X 4.00hexhd Pln Gr 5 Pld Washer, Flat.656 Id X.50 Od X.187t Stl Pld Bracket, Mtg Engine Rh (Deutz 011 Engines) Retainer, Mount Eng/Gen Tubing, Stl.875 Od X 1ga Wall X Mount, Eng/Gen Nprn.875 Id X.500 Od X Nut, hex.76h Stl Pld Elastic Stop Nut Hose Assy, Oil Drain Lg (Consisting Of) Valve, Oil Drain 3/8-18nptf Fitting, Hose Brs Barbed Fem 1/tbg X 3/8npt Hose, Nitrile.500 Id X.765 Od X Roll Blk Brd ft Fitting, Hose Brs Barbed Elbow Fem 1/ Tbg X 1/ Npt Fitting, Adapter Oil Drain Washer, Oil Drain (Available Through Engine Manufacturer) Bracket, Mtg Solenoid (Deutz 011 Engines) (Prior to MF040091E) Bracket, Mtg Solenoid (Eff w/mf040091e) Base, Fuel Filter Assy Fitting, Hose Brs Barbed Elbow M 5/16tbg X 1/4npt Hose, Sae.31 Id X.560 Od X Hose, Sae.31 Id X.560 Od X * Filter, Fuel Spin-On Keeper, Latch Engine Access Door Channel, Stiffener Engine Access Channel, Stiffener Engine Access E-Coat... 1 TM-448 Page 153

26 Eff w/serial LJ Thru MG06006E Figure Main Assembly (Continued) Latch, Paddle Series 0 (Black) Label, Maintenance Big Blue Deutz Series Ce (Prior to LJ004970) Label, Maintenance Big Blue Deutz Series (Eff w/lj004970) Door, Engine Access Door, Engine Access Ss Hinge, Door Access 180deg Stop, Door (Prior to MC5004E) Bumper, Door Od X.750 High Nprn 50 Duro (Eff w/mc5004e) Panel, Rocker Panel, Rocker Ss Panel, Gen Rh Panel, Gen Rh Ss Bumper, Door Engine Access Kit, Field Fuel Tank (Includes) Tank, Fuel Fuel Line Assy, W/Clamps In Bracket, Holddown Fuel Tank Extrusion, Rubber W/Adhesive X D (Order By Ft)... 6ft Bracket, Mtg Unit Bracket, Hold Down Fuel Tank Label, Warning Do Not Weld On Base (Prior to MF51004E) Label, Warning Do Not Weld On Base (En/Fr Sym) (Eff w/mf51004e) C C Panel, Mtg Components R4... C C Resistor, Ww Fxd 375w 50 Ohm W/Mtg Bkt R Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt R3... C C Resistor, Ww Tap 375w 10 Ohm W/Mtg Bkt Figure 15-, Figure 15-3 Control Box Assembly Firewall, Lower Figure Main Rectifier Assembly Top, Cover Front Upright Top, Cover Front Upright Ss Upright, Front Upright, Front Ss Label, Warning General Precautionary Csa (Prior to MF51004E) Label, Warning General Precautionary (En/Fr Sym) (Eff w/mf51004e) Figure 15-4, Figure 15-5 Panel, Front W/Components Figure 15-6 Figure 15-9 Auxiliary Power Group Xfmr, Current Sensing C V Bracket, Mtg Box Fcr PC1.. C V Module, Field Current Regulator Nut,.50-0 U-Nut Multi-Thread Nut, U-Nut Multi-Thread Kit, Label (Includes Safety & Informational Labels) (Cc Models) Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Models) Kit, Label (Includes Safety & Informational Labels) (Cc Export Models)... (Deutz 011 Engines) (Prior to MF51004E) Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Export Models)... (Deutz 011 Engines) (Prior to MF51004E) Kit, Label (Includes Safety & Informational Labels) (Cc Export Models)... (Deutz 91 Engines) (Prior to MF51004E) Kit, Label (Includes Safety & Informational Labels) (Cc/Cv Export Models)... (Deutz 91 Engines) Engine, Deutz Dsl Elec F3L Filter, Fuel Filter Kit, Deutz (91/914) * Filter, Oil (Deutz 91 Engines) * Belt, Blower (Deutz 91 Engines) * Switch, Pressure Oil 1.5 Bar Nc Cont... 1 TM-448 Page 154

27 Eff w/serial LJ Thru MG06006E Figure Main Assembly (Continued) * Sender, Coolant Temp & 130 Degee C Switch Backplate, Deutz 91 Engines Support, Front Engine (Deutz 91 Engines) FS Shutdown Kit, Engine (Deutz 91 Engines) Ftg, Adapter Oil Drain (Deutz 91 Engines) Manifold, Exhaust Muffler (Deutz 91 Engines) Baffle, Lower Air Outlet (Deutz 91 Engines) Baffle, Upper Air Outlet (Deutz 91 Engines) Baffle, Air Intake (Deutz 91 Engines) Hose, Air Cleaner (Deutz 91 Engines) Box, Air Intake (Deutz 91 Engines) Guard, Starter Hole (Deutz 91 Engines) Washer, Flat 6.5idx11.50odx.06t Buna N (Deutz 91 Engines) Label, Stick Overlap Weld Ranges Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit) (Prior to MF51004E) Label, Danger Using Generator Indoor (En/Fr/Sp Sym) (Eff w/mf51004e) Label, Hour/Fuel Meter Usage When ordering a component originally displaying a precautionary label, the label should also be ordered. * Recommended Spare s. Optional C C CC models only. C V CC/CV models only. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 155

28 Eff w/serial LJ Thru MG06006E D Figure 15-. Control Box Assembly CC Models Figure 15-. Control Box Assembly CC Models (Figure ) F1, F.. * Fuse, Mintr Cer Slo-Blo 10A 50V Holder, Fuse Mintr.50 X Control Box, Lh Control Box, Rh Cover, Control Box C Capacitor, Polyp Met Film 10. uf 50 VAC 10% CR Relay, Ocv Control D8/C8, D Diode/Capacitor Board SR1, SR Rectifier, Integ 40A 800V CR Relay, Encl 1VDC Dpst No 5A 6pin Flange CB11, 1, Supplementary Protector, Man Reset 1p 15A 50VAC Clamp, Capacitor 1.375dia C Capacitor, Elctlt 40uF 00VDC R Resistor, Ww Fxd 30 W 5 Ohm Faston Te PC Module, Pull To Idle, Two Output, 7 Pin CR Relay, Encl 1VDC Dpdt 0A/10VAC 8pin Flange Mtg CR Relay, Encl 1VDC Spst 30A/15VDC 5pin Flange Mtg CR Relay, Encl 1VDC Spst 30A/15VDC Spin Flange Mtg D1/C1,D8/C Diode/Capacitor Board CB Circuit Breaker, Auto Reset 1VDC 40A CR Relay, Encl 6VDC Spst 35A/14VDC 5 Pin (Prior to MC030001E) CR Relay, Encl 1VDC Spst 35A/14VDC 5 Pin (Eff w/mc030001e) CB Circuit Breaker, Auto Reset 1VDC 1 Amp CR Relay, Encl 1VDC Spst 70A 4pin Flange Mtg CR Relay, Encl 1VDC Spst 30A/15VDC 5pin Flange Mtg (Prior to LJ005955) R Resistor, Hsc 30 W 3 Ohm (Prior to MA340014E)... 1 Optional *Recommended Spare s. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement s. Model and serial number required when ordering parts from your local distributor. TM-448 Page 156