Welder User Manual

ManualsBrandsGenie ManualsWelding System106730

Part No. 106730

Rev A1

April 2006

Parts and Service

Manual Supplement

Welder

Summary of content (35 pages)

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Parts and Service Manual Supplement Welder Part No.
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April 2006 Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice. Readers are encouraged to notify Genie of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.
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April 2006 Table of Contents This manual is updated frequently. Each parts figure listed below has a figure number and a revision letter. If a figure is updated with new information, the revision letter or ‘Rev’ is updated (example: from Rev A to Rev B). Figure 101.1 Rev Description B Decals If you have a printed manual, you can keep it up to date by downloading new figures from the Genie website. To learn about the benefits Genie eBusiness customers receive, visit the Genie Industries website at www.
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April 2006 This page intentionally left blank. Welder Supplement Part No.
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100 • Parts April 2006 Safety Rules Danger Failure to obey the instructions and safety rules in the Lincoln Electric Invertec™ V275-S Operator’s Manual will result in death or serious injury. Many of the hazards identified in the operator’s manual are also safety hazards when maintenance and repair procedures are performed. Do Not Perform Maintenance Unless: You are trained and qualified to perform maintenance on this machine.
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100 • Parts Figure 101.1 April 2006 Rev A Description S-40 and S-45 Chassis Components, Engine Side 1 2 3 6 38 5 4 5 7 10 9 8 13 12 12 11 37 16 15 14 17 36 31 32 33 34 35 30 31 32 1 18 26 29 28 27 25 21 24 23 22 20 Welder Supplement 19 Part No.
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100 • Parts April 2006 S-40 and S-45 Chassis Components, Engine Side Item Part No. Description Qty. Item Part No. Description 101.1 Rev A Qty. 1 82237 Decal - Danger, High Voltage ...... 2 24 106073 2 106113 25 33607 Relay, 12V DC, DPDT .................. 1 — 106274 Hydraulic Generator Assembly (includes item 38) ......................... 1 Generator, 12.5 kW Circuit Breaker, 20A, Single Phase ................................ 1 26 33608 Relay Socket ..............................
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100 • Parts Figure 102.1 April 2006 Rev A Description S-60 and S-65 Chassis Components 1 2 3 4 25 26 27 22 23 23 24 21 12 13 20 7 6 5 8 19 1 6 9 10 6 5 17 18 13 12 11 16 15 14 Welder Supplement Part No.
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100 • Parts April 2006 S-60 and S-65 Chassis Components Item Part No. Description Qty. Item Part No. Description 102.1 Rev A Qty. 1 82237 Decal - Danger, High Voltage ...... 2 22 6888 Screw - HHC, 1/4 -20 x 1 inch, GR 5 2 106113 23 6638 Flat Washer, 1/4 inch — 106274 Hydraulic Generator Assembly (includes item 3) ........................... 1 Generator, 12.5 kW 24 6091 Nylock Nut, 1/4 -20 3 106184 Hydraulic Motor, 21cc .................. 1 25 9145 Screw - HHC, 1/2 -13 x 2.
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0 • Parts Figure 103.1 April 2006 Rev A 1 Description Z-60 Chassis Components 2 5 6 8 9 10 7 3 11 12 4 14 15 16 17 13 28 27 26 11 12 13 13 12 18 25 13 12 11 19 20 13 12 11 21 22 13 13 12 11 12 24 11 Welder Supplement 23 Part No.
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100 • Parts April 2006 Z-60 Chassis Components Item Part No. Description 1 102314 2 36294 Qty. 103.1 Rev A Item Part No. Description Qty. Enclosure Panel ........................... 1 23 106415 Screw - HHC, 1/4 -20 x 2.75 inches, GR 5 Generator Mount Bracket, Bottom .......................................... 1 24 106184 Hydraulic Motor, 21cc .................. 1 3 6638 Flat Washer, 1/4 inch 25 106479 Generator Cover ..........................
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100 • Parts Figure 104.1 April 2006 Rev A Description S-80, S-85 and Z-80 Chassis Components 1 2 3 5 4 6 7 10 9 8 12 11 13 14 34 35 35 36 31 32 33 29 30 3 4 25 26 27 28 25 4 24 Welder Supplement 23 22 21 19 17 20 18 16 3 15 Part No.
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100 • Parts April 2006 S-80, S-85 and Z-80 Chassis Components Item Part No. Description 1 106184 2 106113 — Qty. 104.1 Rev A Item Part No. Description Hydraulic Motor, 21cc .................. 1 24 106077 25 106104 O-ring, 1inch NPT ......................... 2 106274 Hydraulic Generator Assembly (includes item 1) ........................... 1 Generator, 12.5 kW Squeeze Connector, 0.63 - 0.75 inch ...............................................
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100 • Parts Figure 105.1 April 2006 Rev B Description Platform Components, all Models 9 10 11 12 8 7 6 5 4 Welder Supplement 3 2 1 Part No.
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100 • Parts April 2006 Platform Components, all Models Item Part No. Description Qty. — — — 88406 82862 97579 — 32728 1 106112 Plug, 4 Wire, 3-Phase, 50A .......... 1 2 106111 — — 106110 101732 Locking Receptacle, 3-Phase, 50A ............................................... 1 T-Box, 3-Phase Weatherproof Cover 3 82237 Decal - Danger, High Voltage ...... 2 4 — — — 101731P 4828 5397 106044 Receptacle Bracket ......................
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July 2004 200 • Schematics and Hose Drawings Electrical Schematic N M L K J I H G F E D C B A 1 Theory of Operation P25FS-RD P26FS-BK P24FS-WH RPM HI 20 15 RPM LO ALC-500 16 GENERATOR ON TS4 1. Turning on the Generator supplies current to the high idle relay FOOTSWITCH TS47 through the diode switching the engine to high RPM. In addition the diode between TB45 and TB29 supplies power to the motor stroke valve switching the motors to high speed/low torque mode. 2 2.
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July 2004 Figure 201.
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200 • Schematics and Hose Drawings Figure 202.1 Rev A July 2004 Description S-60 and S-65 Hoses and Fittings 2 B 1 SWV 3 4 DRIVE PUMP 6 5 WELDER MANIFOLD 2 A 1 FUNCTION MANIFOLD 5 CLR PMP B PMP A LEGEND FITTING 0.031 HOSE ASSEMBLY CONNECTOR 21 GPM 5 MTR A MTR B 10 G1 7 7 9 9 8 TO AUX SUCTION 11 21CC 7 3 G2 7 1 5 270 PSI @ 3.5 GPM HYDRAULIC ROTARY COUPLER 12 13 7 G2 G1 12.5 KW GENERATOR Welder Supplement Part No.
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0 • Schematics and Hose Drawings July 2004 S-60 and S-65 Hoses and Fittings Item Part No. Description 202.1 Rev A Qty. 1 89871-4048 Hose Assembly - Components: Genie part numbers 48841, 48841 and 94358 @ 38 inches ... 2 2 48977 Fitting ............................................ 2 3 48948 Fitting ............................................ 1 4 49183-8492 Hose Assembly - Comonents: Genie part numbers 48822, 48822 and 48756 @ 83 inches ... 1 5 48963 Fitting ..........................
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200 • Schematics and Hose Drawings Figure 203.1 Rev A July 2004 Description S-40 and S-45 Hoses and Fittings 2 B 1 SWV 3 4 DRIVE PUMP 7 6 WELDER MANIFOLD 2 A 5 FUNCTION MANIFOLD 6 CLR PMP B PMP A LEGEND FITTING 0.031 HOSE ASSEMBLY CONNECTOR 8 MTR A MTR B 10 G1 21 GPM 9 9 11 11 13 21CC TO AUX SUCTION 12 14 9 3 G2 9 1 8 270 PSI @ 3.5 GPM HYDRAULIC ROTARY COUPLER 15 16 16 G2 G1 12.5 KW GENERATOR Welder Supplement Part No.
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200 • Schematics and Hose Drawings July 2004 S-40 and S-45 Hoses and Fittings Item 1 Part No. Description 203.1 Rev A Qty. 102313-2726 Hose Assembly - Components: Genie part numbers 48841, 48845 and 94358 @ 24 inches ... 1 2 48977 Fitting ............................................ 2 3 67371 Fitting ............................................ 1 4 31070-3750 Hose Assembly - Components: Genie part numbers 48827, 48836 and 48756 @ 35 inches ...
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200 • Schematics and Hose Drawings Figure 204.1 Rev A July 2004 Description S-80 and S-85 Hoses and Fittings 2 B 1 SWV 3 4 DRIVE PUMP 6 5 WELDER MANIFOLD 2 A 1 FUNCTION MANIFOLD 5 CLR PMP B PMP A LEGEND FITTING 0.031 HOSE ASSEMBLY CONNECTOR 6 MTR A MTR B 7 G1 21 GPM 5 5 8 8 10 21CC TO AUX SUCTION 7 11 9 3 G2 9 1 6 270 PSI @ 3.5 GPM HYDRAULIC ROTARY COUPLER 12 13 13 G2 G1 12.5 KW GENERATOR Welder Supplement Part No.
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200 • Schematics and Hose Drawings July 2004 S-80 and S-85 Hoses and Fittings Item 1 Part No. Description 204.1 Rev A Qty. 102313-3126 Hose Assembly - Components: Genie part numbers 48841, 48851 and 94358 @ 28 inches ... 2 2 — 48978 48976 Fitting (before serial no. 3804) ..... 2 Fitting (after serial no. 3803) 3 48961 Fitting ............................................ 1 4 61070-8652 Hose Assembly - Components: Genie part numbers 48827, 48836 and 48756 @ 84 inches ...
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200 • Schematics and Hose Drawings Figure 205.1 Rev A July 2004 Description Z-60/34 Hoses and Fittings 2 B 1 SWV 3 4 DRIVE PUMP 7 6 WELDER MANIFOLD 2 A 5 FUNCTION MANIFOLD 2 CLR PMP B PMP A LEGEND FITTING 0.031 HOSE ASSEMBLY CONNECTOR 2 MTR A MTR B 6 6 9 G1 21 GPM 8 10 11 12 TO AUX SUCTION 13 21CC 8 6 G2 14 6 3 G2 6 1 2 270 PSI @ 3.5 GPM HYDRAULIC ROTARY COUPLER 15 6 8 G1 12.5 KW GENERATOR Welder Supplement Part No.
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200 • Schematics and Hose Drawings July 2004 Z-60/34 Hoses and Fittings Item Part No. Description 205.1 Rev A Qty. 1 94374-4830 Hose Assembly - Components: Genie part numbers 48841, 48846 and 94358 @ 44 inches ... 1 2 48959 Fitting ............................................ 5 3 48964 Fitting ............................................ 1 4 49142-13762 Hose Assembly - Components: Genie part numbers 48842, 48839 and 48756 @ 135 inches ...............................
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200 • Schematics and Hose Drawings Figure 206.1 Rev A July 2004 Description Z-80/60 Hoses and Fittings 2 B 1 SWV 3 4 DRIVE PUMP 7 6 WELDER MANIFOLD 2 A 5 FUNCTION MANIFOLD 6 CLR PMP B PMP A LEGEND FITTING 0.031 HOSE ASSEMBLY CONNECTOR 6 MTR A 8 8 10 11 13 21CC 16 G2 TO AUX SUCTION 12 14 6 3 MTR B 9 G1 21 GPM 6 1 6 270 PSI @ 3.5 GPM G2 HYDRAULIC ROTARY COUPLER 15 16 G1 12.5 KW GENERATOR Welder Supplement Part No.
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200 • Schematics and Hose Drawings July 2004 Z-80/60 Hoses and Fittings Item Part No. Description 206.1 Rev A Qty. 1 49156-3556 Hose Assembly - Components: Genie part numbers 48849, 48853 and 48763 @ 32 inches ... 1 2 48978 Fitting ............................................ 2 3 48964 Fitting ............................................ 1 4 102355-6650 Hose Assembly - Components: Genie part numbers 48826, 48836 and 48756 @ 64 inches ...
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200 • Schematics and Hose Drawings Figure 207.
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200 • Schematics and Hose Drawings July 2004 Hydraulic Hose and Fitting Cross-reference Genie PN Parker PN Description Genie PN Parker PN Description 48813 1J143-6-6 HOSE END,90º FEMALE SWIVEL,SEAL LOK 48875 6 R6LO-S RUN TEE,SWIVEL NUT,ORFS 48814 1J543-6-6 HOSE END,90º FEMALE SWIVEL,SEAL LOK 48877 4 F5OLO-SW/.
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200 • Schematics and Hose Drawings Figure 207.
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200 • Schematics and Hose Drawings July 2004 Hydraulic Hose and Fitting Cross-reference Genie PN Parker PN Description Genie PN 49519 16-12 F5OLO-S CONNECTOR,STRAIGHT THREAD TO ORFS 54428 8M18C87OMLO-S 49520 4 VTX-S ELBOW,45º,MALE PIPE TO FLARE TUBE 54803 FS-F-16-10 49530 16 C6LO-S ELBOW,90º,SWIVEL NUT ORFS 54954 10143-2-4 HOSE END, MALE PIPE 49612 PKT02586 O-RING KIT (ORFS FITTINGS) 55190 3/8 HP-S PLUG,PIPE THREAD 49613 PKT06276 PLUG AND CAP KIT-SERVICE,ORFS 55448 8 HLO-S U
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200 • Schematics and Hose Drawings Figure 207.
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200 • Schematics and Hose Drawings July 2004 Hydraulic Hose and Fitting Cross-reference Genie PN Parker PN Description Genie PN 83057 33782-6-6 HOSE END,45º FEMALE SWIVEL,JIC 88939 1J988-16-16 Parker PN 83058 33982-6-6 HOSE END,90º FEMALE SWIVEL,JIC 88940 811-16 83060 33982-12-12 HOSE END,90º FEMALE SWIVEL,JIC 88944 1J988-20-20 83063 13743-4-4 HOSE END,45º FEMALE SWIVEL,JIC 89403 16 VLO-S 83064 13743-8-8 HOSE END,45º FEMALE SWIVEL,JIC 89449 6 WJJLO-WLNL-S RUN TEE, BULKHEAD,ORF
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Phone Toll Free 425.881.1800 USA and Canada 800.536.1800 Fax Genie Holland Phone Fax 31 70 51 78836 31 70 51 13993 Genie Denmark Phone Fax 45 6612 5544 45 6612 5530 Genie France Phone Fax 33 2 37 26 09 99 33 2 37 31 11 95 Genie Spain Phone Fax 34 93 579 5042 34 93 579 5059 Genie Germany Phone Fax 49 4202 8852-0 49 4202 8852-20 Genie U.K. Phone Fax 44 1636 614700 44 1636 611090 Genie Mexico City Phone Fax 52 5 653 03 84 52 5 664 40 16 425.883.3475 Genie Australia Pty Ltd.