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250 A 250 A, 25 V, 100% Duty Cycle 72 275 A, 25 V, CV/DC 17 . 28 V 60% Duty Cycle 250 A, 28 V, 41 100% Duty Cycle OM-217 455 Page 12 A complete Parts List is available at OM-217 455 Page 13 4-2. Dimensions, Weights, and Operating Angles Dimensions Height 35-1/2 in (902 mm) (To Top Of Exhaust) A B Width 20 in (508 mm) C ! D d il l i ld Depth 53 in (1346 mm) D Do not exceed tilt angles or engine could be damaged or unit could tip. A 20 in (508 mm) 4 H l G ! Do not move or operate unit where it could tip. B 16-1/2 in (419 mm) Holes C 1-3/4 in (44 mm) E F D 6-1/16 in (154 mm) 20° E 32-3/4 in (832 mm) 20° 20° F 51-3/8 in (1305 mm) 20° 20 G 13/32 in (10 mm) Dia. Weight Engine End 700 lb (318 kg) Lifting Eye Weight Rating 1280 lbs (580 kg) 800 426 804 249-A 4-3. Dimensions For Units With Optional Running Gear Dimensions Height All Running Gear Options: 42-1/2 in (1079 mm) (To Top Of Handle Assembly) C A Protective Cage Width: 26 in (660 mm) D B Running Gear Width: 32 in (813 mm) C Protective Cage Length: 48 in (1219 mm) A B D Running Gear Length: 45.1/2 in (1156 mm) B A complete Parts List is available at OM-217 455 Page 14 SECTION 5 . INSTALLATION install2 12/06 . Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712 ! Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. ! Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. ! Do not mount unit by supporting the base only at the four mounting holes. Use crosssupports to adequately support unit and prevent damage to base. ! Always ground generator frame to vehicle frame to prevent electric shock and static electricity hazards. ! If unit does not have GFCI receptacles, use GFCI-protected extension cord. NOTICE . Do not install unit where air flow is restricted or engine may overheat. Mounting: 1 Cross-Supports Mount unit on flat surface or use cross-supports to support base. Grounding: 2 Equipment Grounding Terminal (On Front Panel) 3 Grounding Cable (Not Supplied) 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame. Use #10 AWG or larger insulated copper wire. Electrically bond generator frame to vehicle frame by metal-to-metal contact. GND/PE 2 3 4 OR 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Movement Location / Airflow Clearance Grounding ! Do not lift unit from end. 5-1. Installing Welding Generator Mounting 1 Inadequate support. ! Do not use flexible mounts. OR ! Bed liners, shipping skids, and some running gears insulate the welding generator from the vehicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown. OR A complete Parts List is available at OM-217 455 Page 15 5-2. Installing Exhaust Pipe 804 196-A / Ref. 228 647-A ! Stop engine and let cool. ! Do not blow exhaust toward right side of unit where air inlet is or air cleaner may require frequent service. Point exhaust pipe in desired direction but always away from front panel and direction of travel. Tools Needed: 1/2 in 5-3. Connecting the Battery 804 250-A / Ref 228 647 / Ref. S-0756-D 1/2 in Tools Needed: + . ! Connect negative (.) cable last. A complete Parts List is available at OM-217 455 Page 16 5-4. Overview And Engine Prestart Checks 1 Generator Power Receptacles (see Section 7) 2 Weld Output Terminals (see Section 5-5) 3 Operator Controls (see Section 6) 4 Fuel Gauge/Maintenance Display 5 Fuel Filler Cap 6 Exhaust Pipe 7 Radiator Cap 8 Engine Maintenance Label (Inside Door) 9 Oil Fill Cap 10 Thermostat Housing Plug 11 Oil Filter 12 Coolant Overflow Bottle 13 Oil Drain 14 Oil Dipstick 15 Inline Fuel Strainer 16 Air Cleaner 17 Fuel Filter 18 Fuel Shut Off Valve 7 6 5 4 3 2 1 8 10 9 A complete Parts List is available at OM-217 455 Page 17 12 11 15 16 17 18 ! Engine shown with doors removed. Doors must be in place when engine is running. Engine Left Side Engine Right Side Engine must be cold and on a level surface. See maintenance label (Section 9-2) for fluid specifications. Starting engine for the first time: Add fresh fuel to bottom of filler neck. Open fuel shut-off valve. If coolant level is below bottom of radiator filler neck, add coolant to overflow bottle. Run-in period (first 100 hours): Engine may use oil and wetstacking may occur during run-in (see Section 12). Check oil several times daily during run-in. Daily pre-start checks: Add fresh fuel to bottom of filler neck. Check oil. If oil is not up to full mark on dipstick, add oil. Unit is shipped with 10W30 engine oil. Check coolant level in overflow bottle. If coolant is below Low level, add coolant until level in tank is between Low and Full levels. If overflow bottle coolant level was low, check coolant level in radiator (see Section 9-2). Engine d...