Lincoln Electric IM852 CV ADAPTER - Manual (Page 13)

A-6 INSTALLATION
CV ADAPTER
A-6
K385-2 CV ADAPTER TO SAE-400 (DEUTZ)
(Items 1 thru 16)
• TURN THE ENGINE OFF WHILE INSTALLING
THIS ACCESSORY.
• KEEP HANDS, HAIR, CLOTHING AND TOOLS
AWAY FROM MOVING PARTS WHEN STARTING
OR OPERATING ENGINE.
------------------------------------------------------------------------
1. Remove the upper bracket cover. Also, remove
the two fuel tank support mounting bolts on the
side opposite the output terminals (see Figure
12). Remove the breaker and receptacle guards
mounted on the inside of the front control panel.
2. Mount the K385-2 loosely in position as shown in
Figure B and Figure 13 for SAE-400(Deutz)
loosely in position as shown in Figure A. It is
important that the CV Adapter be positioned flush
against the fuel tank rail. Take care not to pinch
any leads or lines.
3. Remove existing brown field lead from the terminal
block located on the control panel reactor box side.
Connect the yellow lead #600 and the white lead
#602 from the CV adapter to this terminal block
screw directly under the red lead from the diode
bridge.
4. Connect the existing brown field lead to the CV
adapter brown lead #509 using a #10 x 1/4” screw
and nut provided. Insulate connection with electrical
tape.
5. Remove existing blue field lead from the terminal
block located on the control panel reactor box side.
Connect the black lead #610 from the CV adapter to
this terminal block screw directly under the black
lead from the diode bridge.
6. Remove the existing blue field lead to the CV adapter
blue lead #503 using a #10 x 1/4” screw and nut pro-
vided. Insulate connection with electrical tape.
7. Separate the white flashing diode lead from the
white hour meter lead at the taped junction (the
flashing diode is mounted on the side of the reac-
tor box located behind the control panel). Connect
the CV Adapter leads 611 to the white flashing
diode lead, 612 to the white hour meter lead, and
tape off lead 613. Insulate all screw connections
with tape.
8. Connect CV Adapter lead marked “Neg” to the
back of the negative output terminal. Connect CV
Adapter lead marked “Positive” to the back of the
positive output terminal. Tape leads to generator
lead bundle for support.
9. Tape or cable tie CV Adapter control cable leads
to lead bundle to secure control cable.
10. The negative generator brush holder, exposed
when upper bracket cover is removed (see Figure
12), is at the 11 o’clock position when the commu-
tator is viewed from the control panel end of
welder. Remove the 5/16 bolt which connects the
existing cable to the negative brush holder. Route
the #2/0 heavy lead which exists from the bottom
of the CV adapter case as shown in Figure 14.
Obtain a 5/16 X 3/4 bolt from the hardware sent
with the CV Adapter and connect the #2/0 heavy
lead which exits from the bottom of the CV
Adapter case, along with the cable removed
above, to the negative brush holder. The #2/0
heavy lead lug should be between the existing
cable lug and the brush holder. On welders with
AC auxiliary power, tape the #2/0 heavy lead to
the alternator exciter lead bundle coming from the
alternator to support lead where possible.
11. Replace bracket cover removed in Step 1. Also,
tighten the CV Adapter which was loosely mount-
ed in Step 2. For the SAE-400 WELD’N AIR the
CV Adapter must be positioned flush against the
fuel tank rail after tightening.
12. Connect lead 31 to unused “WHITE” terminal of
the 120-volt duplex receptacle. Connect lead 32 to
“CB 3” (circuit breaker 2) at the terminal that has
one black lead coming from the 120-volt duplex
receptacle. Connect lead “G” to the ground stud
located on the control panel. (Same location that
the 120-volt duplex receptacle ground lead is con-
nected.)
13. Reinstall the breaker and receptacle guard that
was removed in Step 1. Be sure that the guard
has a clearance of at least 1/2” from any electri-
cally live part. All new and existing leads must be
routed so they are clear of any sharp edges on
the guard.
WARNING