OM-4427
215 622L
2006−01
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging
Description
Engine Driven Welding Generator
R
Big 40 C
R
Big 40 CX
File: Engine Drive
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions (For Wordless Labels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Volt-Ampere Curves For CC Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4. Volt-Ampere Curves For CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-5. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-7. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-8. Optional Three-Phase Generator Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-2. Using Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-4. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-5. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-6. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-7. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-8. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-9. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models . . . . . . . . . . . . . . . . . . . . . 24
5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SECTION 6 − OPERATING WELDING GENERATOR − CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-1. Front Panel Controls For CC Models (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-2. Description Of Front Panel Controls For CC Models (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Remote Amperage Control On CC Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Weld Control/Arc Condition Information Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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TABLE OF CONTENTS
SECTION 7 − OPERATING WELDING GENERATOR − CC/CV MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-1. Front Panel Controls For CC/CV Models (See Section 7-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7-2. Description Of Front Panel Controls For CC/CV Models (See Section 7-1) . . . . . . . . . . . . . . . . . . . . . . 31
7-3. Process/Contactor Switch On CC/CV Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 8 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-1. 120 Volt And 240 Volt Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only) . . . . . . . . . . . . . . . . . . . . . . . . 35
8-3. Optional Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 9 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9-3. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9-4. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9-7. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9-8. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 10 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SECTION 11 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
SECTION 12 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SECTION 13 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
Y
Marks a special safety message.
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
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1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see the
symbol, watch out, and follow the related instructions to avoid the
hazard. The safety information given below is only a summary of
the more complete safety information found in the Safety Stan-
D
Do not touch electrode holders connected to two welding machines at
the same time since double open-circuit voltage will be present.
D
D
D
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or work-
table as near the weld as practical.
Y
Y
Only qualified persons should install, operate, maintain, and re-
pair this unit.
D
D
Insulate work clamp when not connected to workpiece to prevent contact
with any metal object.
Do not connect more than one electrode or work cable to any single weld
output terminal.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists in inverters after stop-
ping engine.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
D
Stop engine on inverter and discharge input capacitors according to
instructions in Maintenance Section before touching any parts.
machine internal circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all metal
parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
D
D
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
D
D
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the arc to
remove welding fumes and gases.
Insulate yourself from work and ground using dry insulating mats or covers
big enough to prevent any physical contact with the work or ground.
D
Do not use AC output in damp areas, if movement is confined, or if there is a
danger of falling.
D
D
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings, cleaners,
and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an air-
supplied respirator. Always have a trained watchperson nearby. Welding
fumes and gases can displace air and lower the oxygen level causing injury
or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapors to form highly toxic and
irritating gases.
D
D
D
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
D
Additionalsafety precautions are required when any of the following electri-
cally hazardous conditions are present: in damp locations or while wearing
wet clothing; on metal structures such as floors, gratings, or scaffolds;
when in cramped positions such as sitting, kneeling, or lying; or when there
is a high risk of unavoidable or accidental contact with the workpiece or
ground. For these conditions, use the following equipment in order present-
ed: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended.
And, do not work alone!
D
D
Do not weld on coated metals, such as galvanized, lead, or cadmium plated
steel, unless the coating is removed from the weld area, the area is well
ventilated, and while wearing an air-supplied respirator. The coatings and
any metals containing these elements can give off toxic fumes if welded.
D
Disconnect input power or stop engine before installing or servicing this
equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
BUILDUP OF GAS can injure or kill.
D
D
Properly install and ground this equipment according to its Owner’s Manual
and national, state, and local codes.
D
D
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved
air-supplied respirator.
Always verify the supply ground — check and be sure that input power cord
ground wire is properly connected to ground terminal in disconnect box or
that cord plug is connected to a properly grounded receptacle outlet.
D
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When making input connections, attach proper grounding conductor first −
double-check connections.
ARC RAYS can burn eyes and skin.
Frequently inspect input power cord for damage or bare wiring — replace
cord immediately if damaged — bare wiring can kill.
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn eyes
and skin. Sparks fly off from the weld.
D
D
D
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
D
Wear an approved welding helmet fitted with a proper shade of filter lenses
to protect your face and eyes from arc rays and sparks when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
If earth grounding of the workpiece is required, ground it directly with a sep-
arate cable.
D
D
Wear approved safety glasses with side shields under your helmet.
D
D
Do not touch electrode if you are in contact with the work, ground, or anoth-
er electrode from a different machine.
Use protective screens or barriers to protect others from flash, glare, and
sparks; warn others not to watch the arc.
Use only well-maintained equipment. Repair or replace damaged parts at
once. Maintain unit according to manual.
D
Wear protective clothing made from durable, flame-resistant material
(leather, heavy cotton, or wool) and foot protection.
OM-4427 Page 1
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WELDING can cause fire or explosion.
HOT PARTS can cause severe burns.
D
D
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Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from the
welding arc. The flying sparks, hot workpiece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or fire. Check and be sure
the area is safe before doing any welding.
To handle hot parts, use proper tools and/or wear
heavy, insulated welding gloves and clothing to pre-
vent burns.
NOISE can damage hearing.
D
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not
possible, tightly cover them with approved covers.
Noise from some processes or equipment can damage
hearing.
D
D
D
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
D
Wear approved ear protection if noise level is high.
Be alert that welding sparks and hot materials from welding can easily go
through small cracks and openings to adjacent areas.
MAGNETIC FIELDS can affect pacemakers.
D
D
Pacemaker wearers keep away.
D
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Watch for fire, and keep a fire extinguisher nearby.
Wearers should consult their doctor before going
near arc welding, gouging, or spot welding opera-
tions.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause
fire on the hidden side.
D
D
Do not weld on closed containers such as tanks, drums, or pipes, unless
they are properly prepared according to AWS F4.1 (see Safety Standards).
CYLINDERS can explode if damaged.
Connect work cable to the work as close to the welding area as practical to
prevent welding current from traveling long, possibly unknown paths and
causing electric shock, sparks, and fire hazards.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully.
D
D
Do not use welder to thaw frozen pipes.
D
D
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, slag, open flames, sparks, and arcs.
Remove stick electrode from holder or cut off welding wire at contact tip
when not in use.
Install cylinders in an upright position by securing to a stationary support or
cylinder rack to prevent falling or tipping.
D
D
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Wear oil-free protective garments such as leather gloves, heavy shirt, cuf-
fless trousers, high shoes, and a cap.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Remove any combustibles, such as a butane lighter or matches, from your
person before doing any welding.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot
work and have a fire watcher and extinguisher nearby.
Use only correct shielding gas cylinders, regulators, hoses, and fittings de-
signed for the specific application; maintain them and associated parts in
good condition.
D
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Turn face away from valve outlet when opening cylinder valve.
FLYING METAL can injure eyes.
Keep protective cap in place over valve except when cylinder is in use or
connected for use.
D
Welding, chipping, wire brushing, and grinding cause
sparks and flying metal. As welds cool, they can
throw off slag.
D
D
Use the right equipment, correct procedures, and sufficient number of per-
sons to llift and move cylinders.
D
Wear approved safety glasses with side shields even
under your welding helmet.
Read and follow instructions on compressed gas cylinders, associated
equipment, and Compressed Gas Association (CGA) publication P-1 listed
in Safety Standards.
1-3. Engine Hazards
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
D
D
Keep away from fans, belts, and rotors.
Keep all doors, panels, covers, and guards closed
and securely in place.
D
Always wear a face shield, rubber gloves, and protec-
tive clothing when working on a battery.
D
Stop engine before disconnecting or connecting bat-
tery cables or servicing battery.
D
Stop engine before installing or connecting unit.
D
D
D
D
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and −) on batteries.
D
Have only qualified people remove doors, panels, covers, or guards for
maintenance and troubleshooting as necessary.
D
To prevent accidental starting during servicing, disconnect negative (−)
battery cable from battery.
Disconnect negative (−) cable first and connect it last.
D
D
Keep hands, hair, loose clothing, and tools away from moving parts.
Reinstall doors, panels, covers, or guards when servicing is finished and
before starting engine.
D
D
Before working on generator, remove spark plugs or injectors to keep
engine from kicking back or starting.
FUEL can cause fire or explosion.
D
Stop engine and let it cool off before checking or add-
ing fuel.
Block flywheel so that it will not turn while working on generator compo-
nents.
D
Do not add fuel while smoking or if unit is near any
sparks or open flames.
HOT PARTS can cause severe burns.
D
D
D
D
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
D
D
D
Do not touch hot engine parts.
Allow cooling period before maintaining.
Wear protective gloves and clothing when working on
a hot engine.
Always keep nozzle in contact with tank when fueling.
OM-4427 Page 2
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BATTERY ACID can BURN SKIN and EYES.
STEAM AND HOT COOLANT can burn.
D
D
D
Do not tip battery.
Replace damaged battery.
D
If possible, check coolant level when engine is cold to
avoid scalding.
D
Always check coolant level at overflow tank, if pres-
ent on unit, instead of radiator (unless told otherwise
in maintenance section or engine manual).
Flush eyes and skin immediately with water.
D
If the engine is warm, checking is needed, and there is no overflow tank,
follow the next two statements.
ENGINE HEAT can cause fire.
D
D
Wear safety glasses and gloves and put a rag over radiator cap.
D
Do not locate unit on, over, or near combustible
surfaces or flammables.
Turn cap slightly and let pressure escape slowly before completely re-
moving cap.
D
Keep exhaust and exhaust pipes way from flam-
mables.
ENGINE EXHAUST GASES can kill.
EXHAUST SPARKS can cause fire.
D
Use equipment outside in open, well-ventilated ar-
eas.
D
D
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in re-
quired areas — see applicable codes.
D
If used in a closed area, vent engine exhaust outside
and away from any building air intakes.
1-4. Compressed Air Hazards
BREATHING COMPRESSED AIR can
cause serious injury or death.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D
D
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
D
D
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can cause burns and injury.
COMPRESSED AIR can cause injury.
D
D
Do not touch hot compressor or air system parts.
Let system cool down before touching or servicing.
D
D
Wear approved safety goggles.
Do not direct air stream toward self or others.
READ INSTRUCTIONS.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can cause injury.
D
D
Read Owner’s Manual before using or servicing unit.
Stop engine and release air pressure before
servicing.
D
Release air pressure from tools and system before
servicing, adding or changing attachments, or open-
ing compressor oil drain or oil fill cap.
D
Use only genuine Miller/Hobart replacement parts.
1-5. Additional Symbols For Installation, Operation, And Maintenance
OVERUSE can cause OVERHEATING.
FALLING UNIT can cause injury.
D
D
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting
to weld again.
D
Use lifting eye to lift unit and properly installed acces-
sories only. Do not exceed maximum lift eye weight
rating (see Specifications).
D
D
Lift and support unit only with proper equipment and
correct procedures.
D
Do not block or filter airflow to unit.
If using lift forks to move unit, be sure forks are long
enough to extend beyond opposite side of unit.
OVERHEATING can damage motors.
STATIC (ESD) can damage PC boards.
D
Turn off or unplug equipment before starting or stop-
ping engine.
D
Put on grounded wrist strap BEFORE handling
boards or parts.
D
Do not let low voltage and frequency caused by low
engine speed damage electric motors.
D
Use proper static-proof bags and boxes to store,
move, or ship PC boards.
D
Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where
applicable.
FLYING SPARKS can cause injury.
TILTING OF TRAILER can cause injury.
D
D
Wear a face shield to protect eyes and face.
D
D
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer accord-
ing to instructions supplied with trailer.
Shape tungsten electrode only on grinder with proper
guards in a safe location wearing proper face, hand,
and body protection.
D
Sparks can cause fires — keep flammables away.
OM-4427 Page 3
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READ INSTRUCTIONS.
ARC WELDING can cause interference.
D
Use only genuine MILLER/Hobart replacement
parts.
D
Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors,
computers, and computer-driven equipment such as
robots.
Be sure all equipment in the welding area is electro-
magnetically compatible.
D
Perform engine and air compressor (if applicable)
maintenance and service according to this manual
and the engine/air compressor (if applicable) manu-
als.
D
D
D
D
D
To reduce possible interference, keep weld cables as short as possible,
close together, and down low, such as on the floor.
H.F. RADIATION can cause interference.
Locate welding operation 100 meters from any sensitive electronic
equipment.
D
High-frequency (H.F.) can interfere with radio naviga-
tion, safety services, computers, and communica-
tions equipment.
Be sure this welding machine is installed and grounded according to this
manual.
D
Have only qualified persons familiar with electronic
equipment perform this installation.
If interference still occurs, the user must take extra measures such as
moving the welding machine, using shielded cables, using line filters, or
shielding the work area.
D
D
The user is responsible for having
a
qualified electrician
promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the equipment at
once.
D
D
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark
gaps at correct setting, and use grounding and shielding to minimize the
possibility of interference.
1-6. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-7. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1, from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
levard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800-463-6727 or
in Toronto 416-747-4044, website: www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036–8002 (phone: 212-642-4900,
website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (phone:
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202-4102 (phone: 703-412-0900, website:
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandards Association, Standards Sales, 178 Rexdale Bou-
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices—phone for Region 5, Chicago, is
312-353-2220,website: www.osha.gov).
1-8. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from
operator as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
OM-4427 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
rom_fre 3/05
Y
Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions.
2-1. Signification des symboles
Ce groupe de symboles signi-
fie Mise en garde ! Soyez vigi-
lant ! Il y a des risques de dan-
SignifieMise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
ger reliés aux CHOCS ÉLEC-
Y
Identifie un message de sécurité particulier.
TRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Repor-
tez-vous aux symboles et aux directives ci-dessous afin de connaître les mesu-
res à prendre pour éviter tout danger.
.
S
i
g
n
i
f
i
e
N
O
T
A
;
n
’
e
s
t
p
a
s
r
e
l
a
t
i
f
à
l
a
s
é
c
u
r
i
t
é
.
2-2. Dangers relatifs au soudage à l’arc
Y
Les symboles présentés ci-après sont utilisés tout au long du présent
manuel pour attirer votre attention et identifier les risques de danger.
Lorsque vous voyez un symbole, soyez vigilant et suivez les directives
mentionnées afin d’éviter tout danger. Les consignes de sécurité pré-
sentées ci-après ne font que résumer l’information contenue dans les
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être
confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particu-
lièrement les enfants.
D
D
D
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la
pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec
tout objet métallique.
D
Une tension DC importante subsiste à l’intérieur des
onduleurs après avoir coupé l’alimentation.
Y
Y
D
Couper l’alimentation du poste et décharger les condensateurs d’entrée com-
me indiqué dans la Section Maintenance avant de toucher des composants.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut provo-
quer une électrocution ou des blessures graves. L’électrode
et le circuit de soudage sont sous tension dès que l’appareil
est sur ON. Le circuit d’entrée et les circuits internes de
l’appareil sont également sous tension à ce moment-là. En
Le soudage génère des fumées et des gaz. Leur inhalation
peut être dangereux pour votre santé.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
l’arc pour l’évacuation des fumées et des gaz de soudage.
soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des
galets d’entraînement et les pièces métalliques en contact avec le fil de soudage
sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un
danger.
D
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.
Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les
instructions du fabricant concernant les métaux, les consommables, les revê-
tements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant
un respirateur à alimentation d’air. Demander toujours à un surveillant dûment
formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent dé-
placer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des
accidents mortels. S’assurer que l’air de respiration ne présente aucun dan-
ger.
Ne pas souder dans des endroits situés à proximité d’opérations de dégrais-
sage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir en présence de vapeurs et former des gaz hautement toxiques
et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé,
plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé
dans la zone de soudure, que l’endroit soit bien ventilé, et en portant un respi-
rateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces
éléments peuvent dégager des fumées toxiques en cas de soudage.
D
D
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant pas de
trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres moyens iso-
lants suffisamment grands pour empêcher le contact physique éventuel avec
la pièce ou la terre.
Ne pas se servir de source électrique à courant électrique dans les zones hu-
mides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire,
se servir de la fonction de télécommande si l’appareil en est équipé.
Des précautions de sécurité supplémentaires sont requises dans des envi-
ronnements à risque comme: les endroits humides ou lorsque l’on porte des
vêtements mouillés; sur des structures métalliques au sol, grillages et écha-
faudages; dans des positions assises, à genoux et allongées; ou quand il y a
un risque important de contact accidentel avec la pièce ou le sol. Dans ces cas
utiliser les appareils suivants dans l’ordre de préférence: 1) un poste à souder
DC semi−automatique de type CV (MIG/MAG), 2) un poste à souder manuel
(électrode enrobée) DC, 3) un poste à souder manuel AC avec tension à vide
réduite. Dans la plupart des cas, un poste courant continu de type CV est re-
commandé. Et, ne pas travailler seul!
D
D
D
D
D
D
D
D
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de non utili-
sation.
D
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à
la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la
norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respira-
teur d’adduction d’air homologué.
D
D
Installer et mettre à la terre correctement cet appareil conformément à son
manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que le
fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du
sectionneur ou que la fiche du cordon est raccordée à une prise correctement
mise à la terre.
LES RAYONS DE L’ARC peuvent pro-
voquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage génère des
rayons visibles et invisibles intenses (ultraviolets et infrarou-
D
D
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise
à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas endom-
magé ou dénudé − remplacer le cordon immédiatement s’il est endommagé −
un câble dénudé peut provoquer une électrocution.
ges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des
étincelles sont projetées pendant le soudage.
D
D
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou
mal épissés.
D
Porter un casque de soudage approuvé muni de verres filtrants approprié
pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1
énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous votre cas-
que.
Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les au-
tres contre les rayonnements les éblouissements et les étincelles ; prévenir
toute personne sur les lieux de ne pas regarder l’arc.
Porter des vêtements confectionnés avec des matières résistantes et ignifu-
ges (cuir, coton lourd ou laine) et des bottes de protection.
D
D
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou
une électrode provenant d’une autre machine.
D
D
D
D
D
Ne pas toucher des porte électrodes connectés à deux machines en même
temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ les
pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D
OM-4427 Page 5
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LE SOUDAGE peut provoquer un in-
cendie ou une explosion.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
D
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant de travailler à
l’équipement.
Le soudage effectué sur des conteneurs fermés tels que des
réservoirs, tambours ou des conduites peut provoquer leur
éclatement. Des étincelles peuvent être projetées de l’arc de
D
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-
ter des gants de soudage et des vêtements épais pour éviter les brûlures.
soudure. La projection d’étincelles, des pièces chaudes et des équipements
chauds peut provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles, une
explosion, un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D
Déplacer toutes les substances inflammables à une distance de 10,7 m de
l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des
protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des
substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et de métal
chaud.
Des étincelles et des matériaux chauds du soudage peuvent facilement
passer dans d’autres zones en traversant de petites fissures et des
ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-
clencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-
voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés
correctement conformément à AWS F4.1 (voir les normes de sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage pour
éviter le transport du courant sur une longue distance par des chemins incon-
nus éventuels en provoquant des risques d’électrocution et d’incendie.
Brancher le câble de masse sur la pièce le plus près possible de la zone de
soudage pour éviter le transport du courant sur une longue distance par des
chemins inconnus éventuels en provoquant des risques d’électrocution,
d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porte-électrode
ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des gants en
cuir, une chemise en matériau lourd, des pantalons sans revers, des chaus-
sures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches telles
qu’un allumeur au butane ou des allumettes.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B
pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.
D
Porter des protections approuvés pour les oreilles si le ni-
veau sonore est trop élevé.
D
D
D
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent d’abord
consulter leur médecin avant de s’approcher des opéra-
tions de soudage à l’arc, de gougeage ou de soudage par
points.
D
D
D
D
D
D
D
Si des BOUTEILLES sont endomma-
gées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz sous
haute pression. Si une bouteille est endommagée, elle peut
exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs
mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des
étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans
un porte-bouteilles pour les empêcher de tomber ou de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électri-
ques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et rac-
cords convenables pour cette application spécifique; les maintenir ainsi que
les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou
de branchement de la bouteille.
Utiliser les équipements corrects, les bonnes procédures et suffisamment de
personnes pour soulever et déplacer les bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement
connexe et le dépliant P-1 de la CGA (Compressed Gas Association) men-
tionné dans les principales normes de sécurité.
D
D
D
D
D
D
D
D
D
D
D
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D
D
D
Le soudage, l’écaillement, le passage de la pièce à la bros-
se en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de re-
D
D
froidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
D
2-3. Dangers existant en relation avec le moteur
D
D
Arrêter le moteur avant d’installer ou brancher l’appareil.
L’EXPLOSION DE LA BATTERIE peut
RENDRE AVEUGLE.
Toujours porter une protection faciale, des gants en caout-
chouc et vêtements de protection lors d’une intervention
sur la batterie.
Seules des personnes qualifiées sont autorisées à enlever les portes, pan-
neaux, recouvrements ou dispositifs de protection pour effectuer, s’il y a lieu,
des travaux d’entretien et de dépannage.
D
D
D
D
D
D
Pour empêcher tout démarrage accidentel pendant les travaux d’entretien,
débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils des organes
mobiles.
Remettre en place les panneaux ou les dispositifs de protection et fermer les
portes à la fin des travaux d’entretien et avant de faire démarrer le moteur.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la mise en
route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une intervention sur le
générateur.
D
D
D
Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.
Eviter de provoquer des étincelles avec les outils en travaillant sur la batterie.
Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicu-
les de démarrage rapide.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en dernier lieu.
D
D
LE CARBURANT MOTEUR peut provo-
quer un incendie ou une explosion.
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
D
Arrêter le moteur avant de vérifier le niveau de carburant
ou de faire le plein.
D
D
Ne pas toucher les parties chaudes du moteur.
Laisser l’ensemble se refroidir avant d’effectuer la
maintenance.
D
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une
flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son
expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout carburant
renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
D
D
D
D
Porter des gants et des vêtements de protection pour travailler sur un
moteur chaud.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
Il est préférable de vérifier le liquide de refroidissement
une fois le moteur refroidi pour éviter de se brûler.
DES ORGANES MOBILES peuvent pro-
voquer des blessures.
D
D
Ne pas approcher les mains des ventilateurs, courroies et
autres pièces en mouvement.
Maintenir fermés et fixement en place les portes, panneaux, recouvre-
ments et dispositifs de protection.
D
Toujours vérifier le niveau de liquide de refroidissement dans le vase d’expan-
sion (si présent), et non dans le radiateur (sauf si précisé autrement dans la
section maintenance du manuel du moteur).
D
OM-4427 Page 6
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D
D
Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon
du radiateur.
Ne pas placer l’appareil sur, au-dessus ou à proximité de
surfaces inflammables.
D
Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle-
ver le bouchon.
D
LES ACCUMULATIONS DE GAZ ris-
quent de provoquer des blessures ou
même la mort.
D
Tenir à distance les produits inflammables de l’échappement.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
Empêcher les étincelles d’échappement du moteur de
provoquer un incendie.
Utiliser uniquement un pare-étincelles approuvé − voir
codes en vigueur.
D
Fermer l’alimentation du gaz protecteur en cas de non
utilisation.
D
D
D
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
rateur d’adduction d’air homologué.
L’ACIDE DE LA BATTERIE peut pro-
voquer des brûlures dans les YEUX et
sur la PEAU.
D
D
D
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
2-4. Dangers liés à l’air comprimé
Le METAL CHAUD lors du coupage et
gougeage plasma peut provoquer un in-
cendie ou une explosion.
RESPIRER L’AIR COMPRIMÉ peut pro-
voquer des blessures graves ou causer
la mort.
D
D
Ne pas couper ou gouger à proximité de produits in-
flammables.
Surveillez et garder un extincteur à proximité.
D
D
Ne pas utiliser l’air comprimé pour respirer.
Utiliser l’air comprimé seulement pour le coupage, gou-
geage et les outils pneumatiques.
DES PIECES CHAUDES peuvent provo-
quer des brûlures et blessures.
Ne pas toucher le compresseur ou d’autres éléments
du circuit air comprimé chauds.
L’AIR COMPRIMÉ peut provoquer
des blessures.
Porter des lunettes de sécurité approuvées.
Ne pas diriger le jet d’air vers d’autres ou soi-même.
D
D
D
D
Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la mainte-
nance.
L’AIR COMPRIME EMMAGASINE ET DES
TUYAUX SOUS PRESSION peuvent provo-
quer des blessures.
Relâcher la pression d’air de l’outillage ou du systè-
me avant d’effectuer la maintenance, avant de chan-
ger ou de rajouter des éléments ou avant d’ouvrir la
purge ou le bouchon de remplissage d’huile.
LIRE LES INSTRUCTIONS.
Lisez le manuel d’instructions avant l’utilisation ou la
maintenance de l’appareil.
D
D
D
Arrêter le moteur et relâcher la pression avant d’ef-
fectuer la maintenance.
Utiliser uniquement des pièces de rechange Miller/Hobart.
D
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
LA CHUTE DE L’APPAREIL peut blesser.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
Utiliser un œilleton de levage pour lever l’appareil et les
accessoires correctement installés. Ne pas dépasser
le poids nominal maximal de l’œilleton (voir les
spécifications).
Ne lever et ne soutenir l’appareil qu’avec de l’équipement
approprié et en suivant les procédures adéquates.
D
D
D
Laisser l’équipement refroidir ; respecter le facteur de
marche nominal.
Réduire le courant ou le facteur de marche avant de
poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
D
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé
de l’appareil.
LE SURCHAUFFEMENT peut endom-
mager le moteur électrique.
Arrêter ou déconnecter l’équipement avant de démarrer ou
d’arrêter le moteur.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre avant de
manipuler des cartes ou des pièces.
D
D
D
Ne pas laisser tourner le moteur trop lentement sous risque d’endommager
le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a
lieu.
D
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer
ou expédier des cartes de circuits imprimes.
D
LES ÉTINCELLES VOLANTES risquent
de provoquer des blessures.
UNE REMORQUE QUI BASCULE peut
entraîner des blessures.
D
Porter un écran facial pour protéger le visage et les yeux.
D
D
Affûter l’électrode au tungstène uniquement à la meuleuse dotée de protec-
teurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte
l’équipementhomologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute substance in-
flammable.
D
D
Utiliser les supports de la remorque ou des blocs pour
soutenir le poids.
Installer convenablement le poste sur la remorque com-
me indiqué dans le manuel s’y rapportant.
OM-4427 Page 7
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LIRE LES INSTRUCTIONS.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
L’énergie électromagnétique risque de provoquer des in-
terférences pour l’équipement électronique sensible tel
que les ordinateurs et l’équipement commandé par ordi-
nateur tel que les robots.
D
D
Utiliser seulement les pièces de rechange d’origine.
Effectuer la maintenance du moteur et du compresseur
(si applicable) suivant ce manuel et le manuel du moteur/
compresseur (si applicable).
D
D
D
Veiller à ce que tout l’équipement de la zone de soudage soit compatible
électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de souda-
ge aussi courts que possible, les grouper, et les poser aussi bas que pos-
sible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement élec-
tronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre conformé-
ment à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il in-
combe à l’utilisateur de prendre des mesures supplémentaires telles que
le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-
tres de ligne ou la pose de protecteurs dans la zone de travail.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
Le rayonnement haute fréquence (H.F.) peut provoquer
des interférences avec les équipements de
radio−navigation et de communication, les services de
sécurité et les ordinateurs.
D
D
D
D
D
D
Demander seulement à des personnes qualifiées familiarisées avec des
équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien quali-
fié les interférences résultant de l’installation.
D
D
D
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des sources
de haute fréquence, maintenir les éclateurs à une distance correcte et
utiliser une terre et un blindage pour réduire les interférences
éventuelles.
2-6. Proposition californienne 65 Avertissements
Y
Les équipements de soudage et de coupage produisent des fumées et
des gaz qui contiennent des produits chimiques dont l’État de Californie
reconnaît qu’ils provoquent des malformations congénitales et, dans
certains cas, des cancers. (Code de santé et de sécurité de Californie,
chapitre 25249.5 et suivants)
Les batteries, les bornes et autres accessoires contiennent du plomb et
des composés à base de plomb, produits chimiques dont l’État de Cali-
fornie reconnaît qu’ils provoquent des cancers et des malformations
congénitales ou autres problèmes de procréation. Se laver les mains
après manipulation.
Pour les moteurs à essence :
Y
Les gaz d’échappement des moteurs contiennent des produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des cancers
et des malformations congénitales ou autres problèmes de procréation.
Pour les moteurs diesel :
Y
Y
Les gaz d’échappement des moteurs diesel et certains de leurs compo-
sants sont reconnus par l’État de Californie comme provoquant des
cancers et des malformations congénitales ou autres problèmes de pro-
création.
2-7. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone
:
:
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou
à
Toronto 416-747-4044, site Internet
ternet : www.global.ihs.com).
www.csa-international.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
RecommendedSafe Practices for the Preparation for Welding and Cutting
of Containers and Piping, American Welding Society Standard AWS F4.1
de Global Engineering Documents (téléphone : 1-877-413-5184, site In-
ternet : www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000,site Internet : www.nfpa.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101(téléphone : 617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de
Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent
of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux
Code for Safety in Welding and Cutting, CSA Standard W117.2, de régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site
Canadian Standards Association, Standards Sales, 178 Rexdale Internet : www.osha.gov).
2-8. Information EMF
Considérations sur le soudage et les effets de basse fréquence et des procédures suivantes :
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de souda-
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
1. Maintenir les câbles ensemble en les tordant ou en les envelop-
pant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
certain souci à propos de tels champs. Cependant, après avoir examiné 3. Ne pas courber pas et ne pas entourer pas les câbles autour de
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la sou-
dure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer les approuve, il est recommandé de suivre les procédures précédentes.
OM-4427 Page 8
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SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions (For Wordless Labels)
1
Remove unit from shipping
crate. Remove Owner’s
Manual from unit. Follow
instructions to install muffler.
S-177 571
1
+
2
3
Read Owner’s Manual. Read
labels on unit.
Use Diesel Fuel only, and fill
fuel tank. Leave room for
expansion.
2
+
4
Warning! Watch Out! There
are possible hazards as
shown by the symbols. Read
Owner’s Manual. Follow
instructions to activate
battery.
3
DIESEL
5
6
Check oil level. Add oil if
necessary.
4
During the first 50 hours of
operation, keep welding load
above 200 amperes. Do not
weld below 200 amperes of
output.
5
7
After the first 50 hours of
operation, change the oil and
oil filter.
0 − 50 h Std.
200A
0 − 200A
50 h Std.
API CD-MIL L 2104D,
CD/SE, CD/SF
3/96
Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
OM-4427 Page 9
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3-3. Symbols And Definitions
Some symbols are found only on export products.
NOTE
Fast (Run, Weld/
Power)
Stop Engine
Starting Aid
Slow (Idle)
Start Engine
Engine Oil
Engine Oil
Pressure
Battery (Engine)
Check Injectors/
Pump
Check Valve
Clearance
Protective Earth
(Ground)
Fuel
Certified/Trained
Mechanic
Positive
Negative
Volts
Welding Arc
Remote
Amperes
Panel/Local
Output
A V
Air Temperature Or
Engine
Alternating
Current
Engine
Temperature
Stick (SMAW)
Welding
Constant Current
(CC)
MIG (GMAW)
Welding
TIG (GTAW)
Single Phase
Time
Hours
Seconds
1
h
s
Read Operator’s
Manual
Do Not Switch
While Welding
Three Phase
Circuit Breaker
3
Engine-Driven,
Three-Phase
Alternator With
Rectifier
Electrode
Connection
G
3
Work Connection
Hertz
Hz
Rated No Load
Conventional
Load Voltage
Rated Load
Speed
Duty Cycle
X
U0
n0
U2
I
Voltage (Average)
n
I2
Rated Idle
Speed
Rated No Load
Speed
Rated Welding
Current
Current
n1
Contactor On
OM-4427 Page 11
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SECTION 4 − SPECIFICATIONS
4-1. Weld, Power, And Engine Specifications
Maximum
Open-
Welding
Mode
Weld Output
Range
Rated Welding
Output
Generator Power
Rating
Fuel
Capacity
Engine
Circuit
Voltage
Export Models:
300 A, 32 Volts DC,
100% Duty Cycle
55 − 500 A
430 A, 37 Volts DC,
60% Duty Cycle
95
(CC Models)
Standard
Single-Phase,
4 kVA/kW, 34/17 A,
120/240 V AC,
50/60 Hz
CC/DC
15 − 500 A
(CC/CV Models)
300 A, 29 Volts DC,
(CV) 100% Duty Cycle
430 A, 36 Volts DC,
(CV) 60% Duty Cycle
25 gal
(95 L)
Three-Phase Generator
Option*
Single-Phase/Three-Phase,
12/15 kVA/kW, 50/36A,
120/240 VAC, 60 Hz
Caterpillar 3024C
Water-Cooled,
Other Models:
400 A, 36 Volts DC,
100% Duty Cycle
Four-Cylinder,
32.6 HP Diesel Engine
CV/DC
450 A, 38 Volts DC,
60% Duty Cycle
(CC/CV
Models
Only)
*In Addition To Standard
4 kVA/kW Generator Power
14 − 40 V
56
500 A,
30 Volts DC (CC),
34 Volts DC (CV),
40% Duty Cycle
4-2. Dimensions, Weights, And Operating Angles
Dimensions
60 in (1524 mm)
Height
(to top of muffler)
G
28-1/2 in (724 mm)
(mtg. brackets turned in)
Width
30-3/4 in (781 mm)
(mtg. brackets turned out)
Y
Y
Do not exceed tilt angles or engine could
be damaged or unit could tip.
Depth
A
65-1/8 in (1654 mm)
65-1/8 in (1654 mm)
56 in (1422 mm)
Do not move or operate unit where it could
tip.
B*
C*
D*
E
46-1/2 in (1181)
A
9-5/8 in (244 mm)
27-1/2 in (699 mm)
1 in (25 mm)
B
C
D
F
30°
G
29-13/16in (757 mm)
H
30°
9/16 in (14 mm) Dia.
4 Holes
20°
20°
H
*
With mounting brackets in center
position. Dimensions vary with
location of mounting brackets.
F
Weight
E
802 161-A
w/ Cat
3024C
No fuel: 1600 lb (726 kg)
W/fuel: 1775 lb (805 kg)
Lifting Eye Weight Rating:
2500 lb (1134 kg) Maximum
OM-4427 Page 12
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4-3. Volt-Ampere Curves For CC Models
The volt-ampere curve shows the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
100
80
60
40
20
0
Ranges:
230 − Max
170 − 365
110 − 225
70 − 130
55 − 85
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
215 081-A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4427 Page 13
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4-4. Volt-Ampere Curves For CC/CV Models
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding generator. Curves of all
other settings fall between the
curves shown.
A. Stick Mode
100
RANGES:
MAX
80
60
40
20
0
155 − 450
115 − 320
75 − 195
40 − 90
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
B. MIG Mode
100
80
60
MAX
40
20
MIN
0
0
100 200 300 400 500 600 700 800 900 1000
DC AMPERES
C. TIG Mode
100
RANGES:
60 − 365
35 − 250
25 − 155
15 − 75
80
60
40
20
0
0
100
200
300
400
500
DC AMPERES
215 080-A / 215 083-A / 215 079-A
OM-4427 Page 14
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4-5. Fuel Consumption
The curve shows typical fuel use
under weld or power loads.
2.50
2.25
2.00
1.75
1.50
1.25
1.00
0.75
0.50
IDLE
0.25
0.00
0
50 100 150 200 250 300 350 400 450 500
DC WELD AMPERES AT 100% DUTY CYCLE
199 032−A
4-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
100% Duty Cycle At 400 Amperes
Y
Exceeding duty cycle can
damage unit and void
warranty.
ContinuousWelding
215 084-A
OM-4427 Page 15
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4-7. AC Generator Power Curve
The ac power curve shows the gen-
erator power in amperes available
at the 120 and 240 volt receptacles.
150 300
125 250
100 200
75 150
50 100
25 50
0
0
0
0
5
10
15
20
25
50
30
60
AC AMPERES IN 240V MODE
10
20 30 40
AC AMPERES IN 120V MODE
193 018
4-8. Optional Three-Phase Generator Curves
The ac power curves show the gen-
erator power available in amperes
at the single-phase 120/240 volt re-
ceptacle or three-phase 240 volt
terminals.
A. 12 kVA/kW Single-Phase AC Output (No Weld Load)
280
260
240
220
200
180
0
10 20 30 40 50 60 70 80 90 100
AC AMPERES
B. 15 kVA/kW Three-Phase AC Output (No Weld Load)
280
260
240
220
200
180
0
10
20
30
40
50
60
70
AC AMPERES
215 086-A / 215 087-A
OM-4427 Page 16
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SECTION 5 − INSTALLATION
5-1. Installing Welding Generator
Y
Always securely fasten weld-
ing generator onto transport
vehicle or trailer and comply
with all DOT and other applica-
ble codes.
Movement
Y
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
If unit does not have GFCI re-
ceptacles,use GFCI-protected
extension cord.
OR
OR
.
f
o
r
l
i
f
t
i
n
g
e
y
e
rating.
.
f
o
r
m
o
u
n
t
i
n
g
information.
Location
Grounding:
1
Equipment Grounding Terminal
(On Front Panel)
2
3
Grounding Cable (Not Supplied)
Metal Vehicle Frame
OR
OR
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger insu-
lated copper wire.
Airflow Clearance
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
18 in
(460 mm)
1
Grounding
2
GND/PE
Electrically bond generator frame to
vehicle frame by metal-to-metal contact.
3
Y
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 termi-
nal to bare metal on the vehicle frame as shown.
install3 6/05 − Ref. 800 652 / Ref. 800 477-A / 803 274
OM-4427 Page 17
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5-2. Using Lifting Eye
1
2
3
Lifting Eye
Nut
Carriage Bolt
1
Raise lifting eye until it snaps in
place. Lower lifting eye when not
needed.
To lock the lifting eye in the upright
position, insert a 3/8-16 x 1-1/2 in
carriage bolt through slot in bracket
and secure with nut (bolt and nut not
supplied).
2
Tools Needed:
3
Ref. 802 311
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4427 Page 18
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5-3. Mounting Welding Generator
Y
Y
Do not weld on base. Weld-
ing on base can cause fuel
tank fire or explosion. Weld
only on the four mounting
brackets or bolt unit down.
Supporting The Unit
Do not mount unit by sup-
porting the base only at the
four
mounting brackets.
Use cross-supports to ade-
quately support unit and pre-
vent damage to base.
2
Mounting Surface:
1
2
Cross-Supports
OR
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brack-
ets.
1
3
1/2 in Bolt And Washer
(Minimum − Not Supplied)
Inadequate support.
4
3/8-16 x 1 in Screws
(Supplied)
To Bolt Unit In Place:
Y
Do not use flexible mounts.
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Mount unit to truck or trailer with 1/2
in (12 mm) or larger hardware (not
supplied).
Using Mounting Brackets
To Weld Unit In Place:
Weld unit to truck or trailer only at
the four mounting brackets.
2
Welding Unit In Place
Bolting Unit In Place
3
2
4
Tools Needed:
9/16 in
install3 6/05 803 274 / 200 864-A /803 602
OM-4427 Page 19
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5-4. Installing Exhaust Pipe
Y
Stop engine and let cool.
.
P
o
i
n
t
e
x
h
a
u
s
t
p
i
p
e
i
n
d
e
s
i
r
e
d
d
i
-
rection but always away from front
panel and direction of travel.
Tools Needed:
1/2 in
Ref. 803 604 / Ref. 215 158
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4427 Page 20
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5-5. Activating The Dry Charge Battery (If Applicable)
Y
Always wear a face shield,
rubber gloves and protective
clothing when working on a
battery.
3
Remove battery from unit.
5
6
Vent Caps
Sulfuric Acid Electrolyte
(1.265 Specific Gravity)
2
7
Well
1
Fill each cell with electrolyte to
bottom of well (maximum).
Y
Do not overfill battery cells.
Wait ten minutes and check electro-
lyte level. If necessary, add electro-
lyte to raise to proper level. Reins-
tall vent caps.
8
Battery Charger
Y
Read and follow all instruc-
tions supplied with battery
charger.
Charge battery for 12 minutes at 30
amperes or 30 minutes at 5 am-
peres. Disconnect charging cables
and install battery.
4
. When electrolyte is low, add
only distilled water to cells to
maintainproper level.
5 A For 30 Minutes
OR
+
−
30 A For 12 Minutes
Tools Needed:
drybatt1 6/05 − S-0886
5-6. Connecting The Battery
.
R
e
i
n
s
t
a
l
l
c
o
v
e
r
a
f
t
e
r
c
o
n
n
e
c
t
i
n
g
b
a
t
t
e
r
y
.
Y
Connect Negative (−) Cable Last.
+
−
Tools Needed:
1/2 in
Ref. 215 158 / 803 605 / S-0756-C
OM-4427 Page 21
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5-7. Engine Prestart Checks
Check radiator coolant
level when fluid is low in
recovery tank.
Full
Capacity:
404.22 Engine: 9.5 qt (9.01L)
Full
Diesel
Full
Coolant Recovery Tank
Hot Full
Cold Full
803 603
Do not run out of fuel or air will enter fuel sys-
tem and cause starting problems. See en-
gine manual to bleed air from fuel system.
freeze to mixture if using the unit in tempera-
tures below −34° F (−37° C).
. Check all engine fluids daily.
Engine must be cold and on a level surface.
Unit is shipped with 20W break-in oil.
Automaticshutdown system stops engine if
oil pressure is too low or coolant tempera-
ture is too high.
Keep radiator and air intake clean and free
of dirt.
Oil
After fueling, check oil with unit on level sur-
face. If oil is not up to full mark on dipstick,
add oil (see maintenance label).
Y
Incorrect engine temperature can
damage engine. Do not run engine
without a properly working thermo-
stat and radiator cap.
. This unit has a low oil pressure shut-
down switch. However, some condi-
tions may cause engine damage before
the engine shuts down. Check oil level
often and do not use the oil pressure
shutdown system to monitor oil level.
Follow run-in procedure in engine manual.
If unburned fuel and oil collect in exhaust
Coolant
Check coolant level in radiator before start-
ing unit the first time. If necessary, add cool-
ant to radiator until coolant level is at bottom
of filler neck.
.
T
o
i
m
p
r
o
v
e
c
o
l
d
w
e
a
t
h
e
r
s
t
a
r
t
i
n
g
:
Use Starting Aid switch (see Section
Check coolant level in recovery tank daily.
If necessary, add coolant to recovery tank
until coolant level is between Cold Full and
Hot Full levels. If recovery tank coolant level
was low, also check coolant level in radiator.
Add coolant if level is below bottom of radia-
tor filler neck.
Keep battery in good condition. Store
battery in warm area.
Fuel
Y
Do not use gasoline. Gasoline will
damage engine.
Use fuel formulated for cold weather
(diesel fuel can gel in cold weather).
Contact local fuel supplier for fuel in-
formation.
The unit is shipped with enough fuel to pre-
vent air from entering fuel system. Add fresh
diesel fuel before starting (see engine main-
tenance label for fuel specifications). Leave
filler neck empty to allow room for ex-
pansion.
Unit is shipped with an engine coolant mix-
ture of water and ethylene glycol base anti-
freeze rated to −34° F (−37° C). Add anti-
Use correct grade oil for cold weather
OM-4427 Page 22
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5-8. Connecting To Weld Output Terminals
MIG and FCAW Welding
Stick and TIG Welding
For MIG and FCAW welding Direct Current
Electrode Positive (DCEP) on CC/CV models,
connect wire feeder cable to Positive (+) termi-
nal on left and work cable to Negative (−) ter-
minal on right. Use Process/Contactor switch
For Stick and TIG welding Direct Current Elec-
trode Positive (DCEP), connect electrode
holder cable to Positive (+) terminal on left and
work cable to Negative (−) terminal on right.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
For Direct Current Electrode Negative
(DCEN), reverse cable connections.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect electrode
holder cable to Electrode (+) terminal on left
and work cable to Work (−) terminal on right.
If equipped with optional Polarity switch or op-
tional Polarity/AC switch, connect wire feeder
cable to Electrode (+) terminal on left and
work cable to Work (−) terminal on right.
Y
1
Stop engine.
Positive (+) Weld Output Terminal
Negative (−) Weld Output Terminal
2
Y
Failure to properly connect weld
cables may cause excessive heat and
start a fire, or damage your machine.
3
4
5
6
Weld Output Terminal
Supplied Weld Output Terminal Nut
Weld Cable Terminal
Copper Bar
Remove supplied nut from weld output termi-
nal. Slide weld cable terminal onto weld output
terminaland secure with nut so that weld cable
terminal is tight against copper bar. Do not
place anything between weld cable termi-
nal and copper bar. Make sure that the sur-
faces of the weld cable terminal and cop-
per bar are clean.
1
2
6
3
Do not place
anything between
weld cable terminal
and copper bar.
4
5
Tools Needed:
3/4 in
Correct Installation
Incorrect Installation
803 602 / 803 778-A
OM-4427 Page 23
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5-9. Selecting Weld Cable Sizes*
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft
(45 m)
200 ft
250 ft
300 ft
350 ft
400 ft
100 ft (30 m) or Less
(60 m) (70 m) (90 m) (105 m) (120 m)
Weld Output
Terminals
Y
Y
Stop engine before
connectingto weld out-
put terminals.
10 − 60% 60 − 100%
Welding
Amperes
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
Do not use worn, dam-
aged, undersized, or
poorly spliced cables.
100
150
200
4 (20)
3 (30)
3 (30)
4 (20)
3 (30)
2 (35)
4 (20)
2 (35)
1 (50)
3 (30)
1 (50)
2 (35)
1/0 (60)
2/0 (70)
1 (50)
1/0 (60)
3/0 (95)
1/0 (60)
3/0 (95)
2/0 (70)
1/0 (60)
3/0 (95) 4/0 (120) 4/0 (120)
2 ea. 2/0 2 ea. 2/0
250
300
350
400
500
2 (35)
1 (50)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
4/0 (120)
2/0 (70)
3/0 (95) 4/0 (120)
(2x70)
(2x70)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0
(2x70) (2x95) (2x95)
1/0 (60)
2/0 (70)
2/0 (70)
3/0 (95)
3/0 (95) 4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 3/0 2 ea. 4/0
(2x70) (2x95) (2x95) (2x120)
1/0 (60)
1/0 (60)
2/0 (70)
4/0 (120)
4/0 (120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 2 ea. 4/0
(2x70) (2x95) (2x120) (2x120)
2 ea. 2/0 2 ea. 3/0 2 ea. 4/0 3 ea. 3/0 3 ea. 3/0
(2x70)
(2x95)
(2x120)
(3x95)
(3x95)
*Chart is a general guideline and may not suit all applications. If cables overheat, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
2
( ) = mm for metric use
S-0007-F−
***For distances longer than those shown in this guide, call a factory applications representative at 920-735-4505.
5-10. Connecting To Remote Amperage Adjust Receptacle RC13 On CC Models
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1
Ref. 154 862-A / 048 720-K / 803 602
OM-4427 Page 24
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5-11. Connecting To Remote 14 Receptacle RC14 On CC/CV Models
Socket*
Socket Information
A
24 volts ac. Protected by circuit
breaker CB5.
24 VOLTS AC
B
Contact closure to A completes
24 volt ac contactor control
circuit.
C
Output to remote control:+10
volts dc in MIG or Stick mode;
0 to +10 volts dc in TIG mode.
D
Remote control circuit common.
REMOTE
OUTPUT
CONTROL
E
DC input command signal: 0 to
+10 volts from min. to max. of
remote control with Voltage/
Amperage Adjust control at
max.
115 volts, 10 amperes, 60 Hz
ac. Protected by circuit breaker
CB6.
I
OR
115 VOLTS AC
Contact closure to I completes
115 volt ac contactor control
circuit.
J
K
Chassis common.
GND
Ref. 803 602
NEUTRAL
G
Circuit common for 24 and 115
volt ac circuit.
*The remaining sockets are not used.
Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
OM-4427 Page 25
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Engine Starting Controls
Starting Aid Switch
6
Engine Coolant Temperature Gauge
(Optional)
10 Stick/TIG Selection Switch
1
Use switch to disable the max OCV circuit
and the arc drive (dig) circuit for scratch start
TIG welding (see max OCV note under Weld
Controls).
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
When switch is in the Stick position, the max
OCV circuit resets Amperage Adjust Control
R1 to maximum when the arc breaks.
7
Engine Oil Pressure Gauge (Optional)
2
Engine Control Switch
Use switch to start and stop engine.
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
To Start:
Also in the Stick position, the arc drive (dig)
circuit provides additional amperage during
low voltage (short arc length conditions) to
prevent “sticking” electrodes.
Y
Do not use ether. Using ether voids
warranty.
Weld Controls
.
M
a
x
O
C
V
C
o
n
t
r
o
l
C
i
r
c
u
i
t
:
T
h
i
s
u
n
i
t
h
a
s
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
When switch is in Scratch Start TIG position,
the max OCV and arc drive (dig) circuits are
disabled and OCV changes when the control
is adjusted.
a max OCV control circuit that resets Am-
perage Adjust control R1 to maximum
when the arc breaks. When an arc is
struck, weld output control returns to the
R1 front panel or combination front panel/
remote control setting. The Amperage
Adjust control adjusts amperage only
when welding and does not adjust open-
circuit voltage.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
11 Amperage Adjust Switch And Remote
Amperage Adjust Receptacle
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
Connect optional remote control to RC13
panel or remote amperage control. For re-
mote control, place switch in Remote position
and connect remote control to Remote Am-
perage Adjust receptacle RC13 (see Sec-
The max OCV circuit is disabled when
the Stick/TIG Selection switch is in
To Stop: turn Engine Control switch to Off
position.
Engine Gauges And Meters
8
Ampere Range Switch
12 Polarity Switch (Optional)
3
Engine Hour Meter
Y
Do not switch under load.
Y
Do not switch under load.
Use hour meter to monitor engine run time to
help schedule maintenance.
Use switch to select weld amperage range.
For most welding applications, use lowest
amperagerange possible to help prevent arc
outages.
Use switch to change weld output. Select ei-
ther DC Electrode Positive (DCEP) or DC
Electrode Negative (DCEN).
4
Fuel Gauge
Use gauge to check fuel level.
Weld Meters
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run posi-
tion.
9
AmperageAdjust Control
13 AC/DC Voltmeter (Optional)
Control adjusts amperage within range se-
lected by Ampere Range switch. Weld output
would be about 168 A DC with controls set as
shown (50% of 110 to 225 A).
Voltmeterdisplays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
5
Battery Voltmeter (Optional)
Use gauge to check battery voltage and moni-
tor the engine charging system. The meter
should read about 14 volts dc when the en-
gine is running, and about 12 volts dc when
the engine is stopped.
14 AC/DC Ammeter (Optional)
.
T
h
e
n
u
m
b
e
r
s
a
r
o
u
n
d
t
h
e
c
o
n
t
r
o
l
a
r
e
f
o
r
reference only and do not represent an Ammeter displays amperage output of the
actual percentage value.
unit.
OM-4427 Page 27
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6-3. Remote Amperage Control On CC Models (Optional)
1
Remote Amperage Adjust
Receptacle RC13
Connect optional remote control to
1
In Example:
Range = 110 to 225 A DC
Example: Combination Remote Amperage Control (Stick)
Percentage Of Range = 50%
Max = About 168 A DC (50% of 110 to 225)
Max (168 A DC)
Min (90 A DC)
Set Switches
Set Range
Set Control
Adjust Optional Remote Control
Ref. 154 862-A / Ref. 181 711-A / 803 602
6-4. Weld Control/Arc Condition Information Label
. Set weld controls as shown to
achieve softer or stiffer arc condi-
tions for different applications.
OM-4427 Page 28
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Notes
OM-4427 Page 29
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Engine Starting Controls
Starting Aid Switch
Use gauge to check battery voltage and moni-
tor the engine charging system. The meter
should read about 14 volts dc when the en-
gine is running, and about 12 volts dc when
the engine is stopped.
. The numbers around the control are for
reference only and do not represent an
actual percentage value.
1
Use switch to energize starting aid for cold
weather starting (see starting instructions fol-
lowing).
11 Voltage/Amperage Adjust Switch And
Remote 14 Receptacle
6
Engine Coolant Temperature Gauge
(Optional)
Use switch to select front panel or remote
voltage/amperage control. For remote con-
trol, place switch in Remote position and con-
nect remote control to Remote 14 receptacle
2
Engine Control Switch
Normal temperature is 180 - 203° F (82 - 95°
C). Engine stops if temperature exceeds 220°
F (104° C).
Use switch to start engine, select engine
speed ( if unit has auto idle option), and stop
engine.
7
Engine Oil Pressure Gauge (Optional)
In Run position, engine runs at weld/power
speed. In Auto position (optional), engine
runs at idle speed at no load and weld speed
with load applied.
12 Polarity Switch (Optional)
Normal pressure is 30 − 60 psi (207 − 414
kPa). Engine stops if pressure is below 10 psi
(69 kPa).
Y
Do not switch under load.
Use Polarity switch to change weld output.
Select either DC Electrode Positive (DCEP)
or DC Electrode Negative (DCEN).
To Start:
Weld Controls
Y
Do not use ether. Using ether voids
warranty.
8
Process/Contactor Switch
13 Polarity/AC Switch (Optional)
switch information.
Y
Y
Electric shock can kill.
. If engine does not start, let engine come
to a complete stop before attempting re-
start.
Do not use AC output in damp areas,
if movement is confined, or if there is
a danger of falling.
9
Ampere Range Switch
Y
Do not switch under load.
Above 325 F (05 C): turn Engine Control
switch to Start. Release Engine Control
switch when engine starts.
Use switch to select weld amperage range.
Y
Use AC output ONLY if required for the
welding process. If AC output is re-
quired, use remote output control if
present on unit.
Use the lowest four ranges for Stick and TIG
welding. Read the upper set of numbers at
each range for Stick welding and the lower set
at each range for TIG welding.
Below 325 F (05 C): push Starting Aid switch
up for 60 seconds. While still holding Starting
Aid switch, turn Engine Control switch to
Start. Release Engine Control switch and
Starting Aid switch when engine starts.
Y
Do not switch under load.
Use the highest range for MIG welding and for
cutting and gouging (CAC-A).
Use Polarity/AC switch to select AC or DC
weld output and DC weld output polarity. For
Direct Current Electrode Negative (DCEN),
turn switch to − (Negative) position. For Direct
Current Electrode Positive (DCEP), turn
switch to + (Positive) position. For weld pro-
cesses that require alternating current (AC),
use AC position.
For most welding applications, use lowest
amperagerange possible to help prevent arc
outages.
To Stop: turn Engine Control switch to Off
position.
Engine Gauges And Meters
10 Voltage/AmperageAdjust Control
3
Engine Hour Meter
With Process/Contactor switch in any Stick or
TIG setting, use control to adjust amperage
within range selected by Ampere Range
switch. With Process/Contactor switch in any
MIG position, use control to adjust voltage.
With Voltage/Amperage Adjust Switch in Re-
mote position, control limits the remote am-
peragein TIG mode, but has no effect in Stick
and MIG modes.
Use hour meter to monitor engine run time to
help schedule maintenance.
Weld Meters
14 AC/DC Voltmeter (Optional)
4
Fuel Gauge
Voltmeterdisplays voltage at the weld output
terminals, but not necessarily the welding arc
due to resistance of cable and connections.
Use gauge to check fuel level.
To check fuel level when engine is not run-
ning, turn Engine Control switch to Run posi-
tion
15 AC/DC Ammeter (Optional)
Weld output would be about 218 A DC with Ammeter displays amperage output of the
controls set as shown (50% of 115 to 320 A). unit.
5
Battery Voltmeter (Optional)
OM-4427 Page 31
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7-3. Process/Contactor Switch On CC/CV Models
1
Process/Contactor Switch
Y
Weld output terminals are ener-
gized when Process/Contactor
switch is in an Weld Terminals
Always On position and the en-
gine is running.
1
Y
DC voltage is still present at the
weld terminals when Process/
Contactor switch is in the Re-
mote On/Off Switch Required −
Stick position and the engine is
running.
Use switch to select weld process and
weld output on/off control (see table be-
Place switch in Remote On/Off Switch
Required positions to turn weld output
on and off with a device connected to
the remote 14 receptacle.
Place switch in Weld Terminals Always
On positions for weld output to be on
whenever the engine is running.
Use Stick position for air carbon arc
(CAC-A) cutting and gouging.
When switch is in a Stick position, the
arc drive (dig) circuit provides addition-
al amperage during low voltage (short
arc length conditions) to prevent “stick-
ing” electrodes.
The arc drive (dig) circuit is disabled
when switch is in MIG or TIG positions.
. Place switch in Weld Terminals Al-
ways On - Stick position when us-
ing optional three-phase generator
. The engine auto idle option does
not work in the Remote On/Off
Switch Required-TIG mode.
Process/Contactor Switch Settings
Switch Setting
Process
Output On/Off Control
Engine Auto Idle (Optional)
Remote On/Off Switch Re-
quired − TIG, HF Required
Or Scratch Start TIG
GTAW With HF Unit, Pulsing
Device, Or Remote Control
At Remote 14 Receptacle
Not Active
Remote On/Off Switch
Stick (SMAW) With Remote On/Off
MIG (GMAW)
At Remote 14 Receptacle
At Remote 14 Receptacle
Electrode Hot
Active
Active
Active
Active
Active
Required − Stick
Remote On/Off Switch
Required − CV Feeder
Using Remote
Weld Terminals Always On −
MIG (GMAW)
Wire
Stick (SMAW),
Air Carbon Arc (CAC-A) Cutting
And Gouging
Weld Terminals Always On −
Electrode Hot
Stick
Weld Terminals Always On −
TIG Scratch Start (GTAW)
Electrode Hot
TIG, Scratch Start
OM-4427 Page 32
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7-4. Remote Voltage/Amperage Control On CC/CV Models (Optional)
1
Remote 14 Receptacle RC14
Connect optional remote control to
1
In Example:
Process = Stick (Using Remote On/Off)
Range = 115 to 320 A DC
Min = 115 A DC
Example: Combination Remote Amperage Control (Stick)
Max = 320 A DC
Max (320 A DC)
Min (115 A DC)
Set Remote
Process
Set V/A
Adjust Switch
Set Range
Control Not
Used In Remote
Stick Mode
Adjust Optional Remote Control
In Example:
Process = TIG (Using Remote On/Off)
Range = 35 to 250 A DC
Example: Combination Remote Amperage Control (TIG)
Percentage Of Range = 50%
Min = 35 A DC
Max = About 143 A DC (50% of 35 to 250)
Max (143 A DC)
Min (35 A DC)
Set Remote
Process
Set V/A
Adjust Switch
Set Range
Set Control
Adjust Optional Remote Control
0774 / Ref. 215 158 / Ref. 803 602
OM-4427 Page 33
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SECTION 8 − OPERATING AUXILIARY EQUIPMENT
8-1. 120 Volt And 240 Volt Receptacles
1
2
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 30 A AC Twistlock
Receptacle RC1
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, GFCI
Reset button pops out and
receptacle does not work. Check
for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
1
2
3
4
. At least once a month, run en-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
3
4
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects RC1 and the genera-
tor winding from overload. If CB1
opens, RC1 and GFCI1 do not
work. Place switch in On position to
reset breaker.
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
. If a circuit breaker continues to
open, contact Factory Autho-
rized Service Agent.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
-
fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624-A
OM-4427 Page 34
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8-2. Connecting To Optional Three-Phase Generator (CC/CV Models Only)
.
P
l
a
c
e
P
r
o
c
e
s
s
/
C
o
n
t
a
c
t
o
r
s
w
i
t
c
h
in Weld Terminals Always On -
Stick position when using three-
phase generator (see Section
7-3).
1
2
Single-Phase Power Connection
Single-PhaseGenerator Power
1
120/240 V 50 A Receptacle
RC5
RC5 is connected to the optional
three-phase generator and supplies
60 Hz single-phase power at weld/
power speed. Maximum output from
RC5 is 12 kVA/kW. Power available
at RC5 is reduced when welding.
2
Circuit Breaker CB7
Circuit breaker CB7 protects single-
phase receptacle RC5 and the load
wires from overload. If CB7 opens, all
generatoroutput stops and the recep-
tacle does not work.
Three-Phase Generator Power
Three-Phase Power Connection
Single
Phase
1
Three
Phase
3
AC
Output
Y
Y
Stop engine.
Volts
120/240
240
Power and weld outputs are
live at the same time. Discon-
nect or insulate unused
cables.
Y
Close panel opening
if no connections are
made to generator.
Amps
KVA/KW
50
12
36
15
Frequency
Engine Speed
60 Hz
1850 RPM
. Have qualified person install ac-
cording to circuit diagram and
Generator Power Guidelines
Lead 42 connects to GROUND stud on
front of unit.
Jumper 42 is connected to 90 at factory.
Remove generator power panel
mountingscrews. Tilt panel forward.
93
3
4
5
6
Lead 93
Lead 92
Lead 91
91
Remove plug
before inserting
leads. Reinstall
bushing.
90
92
Lead 42 (Circuit Grounding
Lead)
4
3
Rear Of Panel
7
8
9
Lead 90 (Neutral)
5
6
Isolated Neutral Terminal
Jumper Lead 42
91
92
93
10 Grounding Terminal
2
Jumper 42 is connected to lead 90 at
factory. Jumper 42 may be discon-
nected from neutral to meet applica-
ble electrical codes.
12
7
Lead 42 connects to front panel
Ground stud.
10
11 User-Supplied Leads
12 Circuit Breaker CB7 User
Terminals
11
Connect user-supplied leads to ter-
minals on CB7 and to the isolated
neutral terminal and grounding termi-
nal as necessary.
Y
Close
panel
opening if no
connections
are made to
generator.
9
8
. Circuit breaker CB7 protects
single-phase receptacle RC5
and the load wires from overload.
If CB7 opens, all generator out-
put stops and the receptacle
does not work.
240V
240V
120V
1-Phase
3-Phase
120V
Tools Needed:
240V
Reinstall generator power panel.
240V
Ref. 197 399 / 802 332-E / 803 655
OM-4427 Page 35
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8-3. Optional Generator Power Receptacles
1
2
3
4
120 V 20 A AC GFCI
Receptacle GFCI1
240 V 16 A AC European
Receptacle RC1
European Receptacle
1
2
5
240 V 15 A AC Australian
Receptacle RC1
240 V 15 A AC South African
Receptacle RC1
6
Receptacles supply 60 Hz single-
phase power at weld/power speed.
If a ground fault is detected, the
GFCI Reset button pops out and
the receptacle does not work.
Check for faulty tools plugged in
receptacle. Press button to reset
GFCI1.
.
A
t
l
e
a
s
t
o
n
c
e
a
m
o
n
t
h
,
r
u
n
e
n
-
gine at weld/power speed and
press test button to verify GFCI
is working properly.
Australian Receptacle
5
1
3
5
6
Circuit Breaker CB2
Circuit Breaker CB3
CB2 protects GFCI1 from overload.
If CB2 opens, GFCI1 does not
work. Press button to reset breaker.
6
CB3 protects RC1 from overload. If
CB3 opens, RC1 does not work.
Press button to reset breaker.
. If a circuit breaker continues to
open, contact Factory Autho-
rized Service Agent.
.
G
e
n
e
r
a
t
o
r
p
o
w
e
r
i
s
n
o
t
a
f
-
fected by weld output.
Maximum output is 2.4 kVA/kW
from GFCI1 and 4 kVA/kW from
RC1. Maximum output from all re-
ceptacles is 4 kVA/kW.
South African Receptacle
5
1
4
EXAMPLE: If 13 A is drawn from
RC1, only 7 A is available at GFCI1:
6
(240 V x 13 A) + (120 V x 7 A) =
4.0 kVA/kW
191 624
OM-4427 Page 36
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9-2. Routine Maintenance
Y
Stop engine before maintaining.
.
S
e
e
E
n
g
i
n
e
M
a
n
u
a
l
a
n
d
M
a
i
n
t
e
n
a
n
c
e
L
a
b
e
l
Recycle engine
fluids.
for important start-up, service, and storage
information. Service engine more often if
used in severe conditions.
n
=
C
h
e
c
k
Z
=
C
h
a
n
g
e
~
=
C
l
e
a
n
l
=
R
e
p
l
a
c
e
Reference
* To be done by Factory Authorized Service Agent
Every
8
Hours
FUEL
WATER
n
F
u
e
l
/
W
a
t
e
r
S
e
p
a
r
a
t
o
r
n
F
u
e
l
L
e
v
e
l
n
O
i
l
L
e
v
e
l
~
O
i
l
,
F
u
e
l
S
p
i
l
l
s
n
C
o
o
l
a
n
t
L
e
v
e
l
Every
50
Hours
~
A
i
r
C
l
e
a
n
e
r
E
l
e
m
e
n
t
~
W
e
l
d
T
e
r
m
i
n
a
l
s
Every
100
Hours
~
B
a
t
t
e
r
y
T
e
r
m
i
n
a
l
s
n
A
i
r
C
l
e
a
n
e
r
H
o
s
e
s
Every
250
Hours
Engine
Manual,
1/2 in.
(13 mm)
l
U
n
r
e
a
d
a
b
l
e
L
a
b
e
l
s
n
F
a
n
B
e
l
t
T
e
n
s
i
o
n
Z
O
i
l
Z
O
i
l
F
i
l
t
e
r
n
~
S
p
a
r
k
A
r
r
e
s
t
o
r
Every
500
Hours
n
l
W
e
l
d
C
a
b
l
e
s
Every
1000
Hours
Engine
FUEL
OR
Manual
SLUDGE
n
R
a
d
i
a
t
o
r
F
l
u
i
d
L
e
v
e
l
~
I
n
s
i
d
e
U
n
i
t
Z
F
u
e
l
F
i
l
t
e
r
~
D
r
a
i
n
S
l
u
d
g
e
n
n
~ Slip Rings*
Brushes*
n
V
a
l
v
e
C
l
e
a
r
a
n
c
e
*
l
Every
2000
Hours
~ Injectors*
OM-4427 Page 38
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9-3. Checking Generator Brushes
Y
Stop engine and let cool.
1
Generator Brush
Mark and disconnect leads at brush hold-
er cap. Remove brushes.
Replace brushes if damaged or if brush
materialis at or near minimum length.
Minimum Length:
5/8 in (16 mm)
New Length: 1-1/4 in (32 mm)
Replace
Damaged Brushes
1
Ref 215 158
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4427 Page 39
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9-4. Servicing Air Cleaner
Y
Y
Stop engine.
Do not run engine without air
cleaner or with dirty element. En-
gine damage caused by using a
damaged element is not covered
by the warranty.
1
3
4
2
.
T
h
e
a
i
r
c
l
e
a
n
e
r
p
r
i
m
a
r
y
e
l
e
m
e
n
t
c
a
n
be cleaned but the dirt holding capac-
ity of the filter is reduced with each
cleaning. The chance of dirt reaching
the clean side of the filter while clean-
ing and the possibility of filter damage
makes cleaning a risk. Consider the
risk of unwarrantable equipment
damage when determining whether
to clean or replace the primary ele-
ment.
Optional
5
If you decide to clean the primary ele-
ment, we strongly recommend instal-
ling an optional safety element to pro-
vide additional engine protection.
Never clean a safety element. Re-
place the safety element after servic-
ing the primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Re-
place primary element if damaged. Re-
place primary element yearly or after six
cleanings.
Keep nozzle
2 in (51 mm)
from element.
1
2
3
4
5
Housing
Safety Element (Optional)
Primary Element
Dust Cap
Dust Ejector
To clean air filter:
Wipe off cap and housing. Remove cap
and dump out dust. Remove element(s).
Wipe dust from inside cap and housing
with damp cloth. Reinstall safety element
(if present). Reinstall cap.
Blow
Inspect
Y
Do not clean housing with air
hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi
(690 kPa). Use 1/8 in (3 mm) nozzle and
keep nozzle at least 2 in (51 mm) from
inside of element. Replace primary ele-
ment if it has holes or damaged gaskets.
Reinstall primary element and cap (dust
ejector down).
aircleaner1 9/00 − ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 215 158
OM-4427 Page 40
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9-5. Inspecting And Cleaning Optional Spark Arrestor Muffler
Y
1
Stop engine and let cool.
Spark Arrestor Muffler
Cleanout Plug
2
Remove plug and remove any dirt
covering cleanout hole.
Start engine and run at idle speed to
blow out cleanout hole. If nothing
blows out of hole, briefly cover end
of exhaust pipe with fireproof
material.
2
Y
Stop engine and let cool.
Reinstall cleanout plug.
1
Tools Needed:
3/8 in
803 656 / Ref. 215 158
OM-4427 Page 41
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9-6. Adjusting Engine Speed On Models With Automatic Idle (Optional)
.
S
e
e
e
n
g
i
n
e
m
a
n
u
a
l
f
o
r
e
n
g
i
n
e
Engine Speed
(No Load)
speed adjustments on standard
models.
1850 rpm max
(61.6 Hz)
After tuning engine, check engine
speed with tachometer or frequency
meter. See table for proper no load
speed. If necessary, adjust speed
as follows:
1250 rpm
(41.6 Hz)
Start engine and run until warm.
On CC models, place Stick/TIG
switch in Stick position.
On CC/CV models, turn Process/
Contactor switch to Stick − Weld
Terminals Always On position.
Idle Speed Adjustment
1
2
Throttle Rod/Plunger
Locknut
Loosen locknut. Place Engine Con-
trol switch in Auto position.
Turn throttle rod and plunger until
engine runs at idle speed. Tighten
locknut.
. Be sure solenoid plunger pulls
all the way in (“bottoms”) when
energized.
. If necessary, move linkage to
other hole in bracket or move
cotter pin to other hole in throttle
arm to set idle speed correctly.
Y
Stop engine.
Weld/Power Speed Adjustment
Weld/powerspeed adjustment must
be done by a Factory Authorized
Service Agent.
If necessary,
move linkage to
other hole in
bracket or move
cotter pin to other
hole in throttle
arm to set idle
speed correctly.
2
1
803 606
OM-4427 Page 42
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9-7. Servicing Fuel And Lubrication Systems
Y
Y
Stop engine and let cool.
After servicing, start engine
and check for fuel leaks.
Stop engine, tighten connec-
tions as necessary, and wipe
up spilled fuel.
1
2
3
4
Oil Filter
4
Oil Drain Valve And Hose
Oil Fill Cap
Fuel Line
5
3
5
Primary Fuel Filter (Fuel/
Water Separator)
6
6
7
8
Petcock
7
Secondary Fuel Filter
Fuel Tank Sludge Drain Valve
To change oil and filter:
Route oil drain hose and valve
through hole in base. See engine
manual and engine maintenance
label for oil/filter change in-
formation.
1
To drain water from fuel system:
Open primary fuel filter petcock and
drain water into metal container.
Close petcock when water-free fuel
flows.
To replace primary fuel filter:
Turn filter counterclockwise. Re-
move filter.
Fill new filter with fresh fuel. Apply
thin coat of fuel to gasket on new fil-
ter. Install new filter and turn clock-
wise. Bleed air from fuel system ac-
cording to engine manual.
Inspect fuel lines, and replace if
cracked or worn.
To replace secondary fuel filter:
See engine manual.
To drain sludge from fuel tank:
2
Y
Beware of fire. Do not smoke
and keep sparks and flames
away from drained fuel. Dis-
pose of drained fuel in an en-
vironmentally-safe manner.
Do not leave unit unattended
while draining fuel tank.
8
Y
Properly lift unit and secure
in a level position. Use ade-
quate blocks or stands to
support unit while draining
fuel tank.
Attach 1/2 ID hose to drain valve.
Put metal container under drain,
and use screwdriver to open
sludge drain valve. Close valve
when sludge has drained. Remove
hose.
Close door.
Tools Needed:
802 490 / Ref. 801 434
OM-4427 Page 43
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9-8. Overload Protection
Y
Stop engine.
.
W
h
e
n
a
c
i
r
c
u
i
t
b
r
e
a
k
e
r
o
r
f
u
s
e
opens, it usually indicates a more se-
rious problem exists. Contact Facto-
ry Authorized Service Agent.
1
2
Fuse F1
Fuse F2
F1 and F2 protect the stator exciter wind-
ing from overload. If F1 opens, weld and
generator power is low or stops entirely.
If F2 opens, weld output is low or stops
entirely. 4 kVA/kW generator power is still
available.
3
4
Circuit Breaker CB4 (Not Shown)
2
1
Circuit Breaker CB5
(CC/CV Models Only)
5
Circuit Breaker CB6
(CC/CV Models Only)
6
7
8
9
Circuit Breaker CB10 (Not Shown)
Circuit Breaker CB11
Circuit Breaker CB12
9
8
Circuit Breaker CB13
7
10 Circuit Breaker CB14 (Not Shown)
CB4 protects the welding arc drive (dig)
circuit. If CB4 opens, electrode may stick
to the workpiece more frequently during
low voltage (short arc length) conditions.
CB4 automatically resets when the fault
is corrected.
CB5 protects the 24 volt ac output to re-
mote receptacle RC14, and 24 volt output
to field current regulator board PC1 (CC/
CV models only). If CB5 opens, weld out-
put and 24 volt output to RC14 stops. On
units with optional three-phase genera-
tor, generator power output at receptacle
RC5 also stops if CB5 opens.
5
4
CB6 protects the 115 volt ac output to re-
mote receptacle RC14 (CC/CV models
only). If CB6 opens, 115 volt output to
RC14 stops.
CB10 protects the engine battery circuit.
If CB10 opens, the engine will not crank.
CB10 automatically resets when the fault
is corrected.
CB11 protects the weld control circuit. On
CC models, if CB11 opens the max OCV
circuit does not work and open circuit
voltage is variable at all times (see max
OCV note under Weld Controls in Section
6-2). If CB11 opens on CV models, weld
output stops (generator power is still
available).
CB12 protects the field flashing circuit. If
CB12 opens, the generator may not ex-
cite at start-up and weld and generator
power output may not be available.
CB13 protects the engine control circuit.
If CB13 opens, the engine does not
crank.
CB14 protects throttle solenoid TS1 on
units with auto idle option. If CB14 opens,
the engine does not run at idle speed.
CB14 automatically resets when the fault
is corrected.
Press button to reset breaker.
803 605
OM-4427 Page 44
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9-9. Troubleshooting
A. Welding − CC Models
Trouble
Remedy
No weld output; generator power output Check position of Ampere Range switch.
okay at ac receptacles.
Check position of optional Polarity switch.
Place Amperage Adjust switch in Panel position, or place switch in Remote position and connect remote
Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte-
grated rectifier SR2 and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and weld excitation circuit.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Check and tighten connections inside and outside unit.
Erratic weld output.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
High weld output.
Low weld output.
Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check OCV control circuit.
Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
check integrated rectifier SR1, capacitor C9, integrated rectifier SR2, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
Place Stick/TIG switch in Stick position.
Maximum weld output only in each Have Factory Authorized Service Agent check control relay CR7.
ampere range (with Stick/TIG Selection
switch in Stick position).
No remote fine amperage control.
Place Amperage Adjust switch in Remote position.
Reset circuit breaker CB11 (see Section 9-8). Have Factory Authorized Service Agent check control relay
CR7.
Repair or replace remote control device.
Have Factory Authorized Service Agent check OCV control circuit.
OM-4427 Page 45
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B. Welding − CC/CV Models
Trouble
Remedy
No weld output; generator power output Place Process/Contactor switch in a Weld Terminals Always On position, or place switch in a Remote
okay at ac receptacles.
On/Off Switch Required position and connect remote contactor to optional Remote 14 receptacle RC14
Check position of Ampere Range switch.
Check position of optional Polarity switch or Polarity/AC switch.
Reset circuit breaker CB5 (see Section 9-8). Check for faulty remote device connected to RC14.
Have Factory Authorized Service Agent check connector board PC6 and connections.
Check fuse F2, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check
brushes and slip rings, weld excitation circuit, field current regulator board PC1, and the rotor.
No weld output or generator power out- Disconnect equipment from generator power receptacles during start-up.
put at ac receptacles.
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
Check and tighten connections inside and outside unit.
Erratic weld output.
Be sure connection to work piece is clean and tight.
Use dry, properly stored electrodes.
Remove excessive coils from weld cables.
Have Factory Authorized Service Agent check brushes and slip rings.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
High weld output.
Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage feed-
back circuit.
Voltage/Amperage control does not Place Ampere Range switch in lower range. Voltage/Amperage control does not work with Ampere
work when welding in Stick mode.
Range switch in highest range.
Low weld output.
Check position of Ampere Range switch and Voltage/Amperage Adjust control.
Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
check integrated rectifier SR1, capacitor C9, field current regulator board PC1, and the rotor.
Electrode sticks to the workpiece more Circuit breaker CB4 may be open. CB4 automatically resets when the fault is corrected (see Section 9-8).
frequently during low voltage (short arc Have Factory Authorized Service Agent check transformer T1 and integrated rectifiers SR4 and SR5.
length) conditions.
Low open-circuit voltage.
Check engine speed, and adjust if necessary.
Check position of Process/Contactor switch.
No remote fine amperage or voltage Place Voltage/Amperage Adjust switch in Remote position.
control.
Repair or replace remote control device.
Have Factory Authorized Service Agent check PC1 current sensing leads (36 and 37), and connections.
work.
Repair or replace wire feeder.
OM-4427 Page 46
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Trouble
Remedy
Low CV weld output.
Set Ampere Range switch to highest range.
Increase Voltage/Amperage Adjust Control setting.
Min or max CV weld output only.
Check position of Voltage/Amperage Adjust control and Voltage/Amperage Adjust switch.
Repair or replace remote control device.
Have Factory Authorized Service Agent check Amperage/Voltage Adjust Control R1, and field current
regulator board PC1.
C. Standard Generator Power
Trouble
Remedy
No generator power output at ac recep- Reset receptacle circuit breakers.
tacles; weld output okay.
Reset GFCI receptacle.
No generator power or weld output.
Disconnect equipment from generator power receptacles during start-up.
check integrated rectifier SR1, capacitor C9, diode/capacitor board D1/C1, and the rotor.
Reset circuit breaker CB12. Have Factory Authorized Service Agent check diode D1 .
Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.
High output at generator power ac re- Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
ceptacles.
Have Factory Authorized Service Agent adjust generator power field current resistor R3.
Low output at generator power ac recep- Check engine speed, and have Factory Authorized Service Agent adjust if necessary.
tacles.
Check fuse F1, and replace if open (see Section 9-8). Have Factory Authorized Service Agent check inte-
grated rectifier SR1, resistor R3, and capacitor C9.
D. Optional Three-Phase Generator Power (CC/CV Models Only)
Trouble
Remedy
No or low output at optional three-
phase generator/receptacle RC5.
Check engine weld/power speed, and have Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
PC1.
High output at optional three-phase
generator/receptacle RC5.
Check engine weld/power speed, and have Factory Authorized Service Agent adjust if necessary.
Have Factory Authorized Service Agent check field current regulator board PC1, and PC1 voltage
feedback circuit.
Erratic output at optional three-phase Have Factory Authorized Service Agent check brushes and slip rings, and field current regulator board
generator/receptacleRC5.
PC1.
OM-4427 Page 47
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E. Engine
Trouble
Remedy
Engine will not crank.
Check battery, and replace if necessary.
Check battery connections and tighten if necessary.
Circuit breaker CB10 may be open. CB10 automatically resets when fault is corrected (see Section 9-8).
Have Factory Authorized Service Agent check engine wiring harness and components.
Check engine wiring harness plug connections.
Have Factory Authorized Service Agent check control relay CR1 and Engine Control switch S1.
Check fuel level.
Engine cranks but does not start.
Check battery and replace if necessary. Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check engine wiring harness, time delay relay TD1, control
relay CR5, fuel pump, fuel solenoid FS1, and diode/capacitor board D10/C10.
Air in fuel system. See engine manual.
Engine starts, but stops when Engine Check oil, and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
Control switch is released.
temperatureis too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after
start-up.
Have Factory Authorized Service Agent check time delay relay TD1, and control relay CR5.
Engine hard to start in cold weather.
Keep battery in good condition. Store battery in warm area off cold surface.
Use fuel formulated for cold weather (diesel fuel can gel in cold weather). Contact local fuel supplier for
fuel information.
Engine suddenly stops.
Check oil and coolant levels. Automatic shutdown system stops engine if oil pressure is too low or coolant
temperatureis too high (see Section 5-7). Automatic shutdown system is inhibited for 30 seconds after
start-up.
See engine manual.
Check fuel level.
Engine slowly stopped and cannot be
restarted.
See engine manual.
Battery discharges between uses.
Turn Engine Control switch off when unit is not running.
Clean top of battery with baking soda and water solution; rinse with clear water.
Recharge or replace battery if necessary.
Periodically recharge battery (approximately every 3 months).
Have Factory Authorized Service Agent check idle module PC7 and current transformer CT1.
Engine idles, but does not come up to
weld speed (models with idle option
only).
Check for obstructed throttle solenoid.
Engine does not run at idle speed
(models with idle option only).
CC models: place Stick/TIG Selection switch in Stick position.
CC/CV models: place Process/Contactor switch in any position but Remote On/Off Switch Required-
TIG.
Check for obstructed throttle solenoid.
Have Factory Authorized Service Agent check idle module PC7, and control relays CR3 and CR6.
wetstacking occurs.
OM-4427 Page 48
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Notes
OM-4427 Page 49
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223 522-B
OM-4427 Page 51
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Figure 10-2. Circuit Diagram For CC/CV Welding Generator
OM-4427 Page 52
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223 523-B
OM-4427 Page 53
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SECTION 11 − RUN-IN PROCEDURE
run_in1 11/05
11-1. Wetstacking
Y
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
1
Welding Generator
Run diesel engines near rated volt-
age and current during run-in period
to properly seat piston rings and
prevent wetstacking. See name-
plate, rating label, or specifications
section in this manual to find rated
voltage and current.
2
. Do not idle engine longer than
necessary. Piston rings seat
faster if engine runs at weld/
power rpm, and the welding
generatoris kept loaded during
run-in.
1
2
Engine Exhaust Pipe
Wetstacking is unburned fuel and
oil in the exhaust pipe and occurs
during run-in if the engine is run too
long at light load or idle rpm.
If exhaust pipe is coated with a wet,
black, tar-like substance, dry the
engine using one of the following
run-in procedures.
See the engine manual for addition-
al engine run-in information.
OM-4427 Page 54
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11-2. Run-In Procedure Using Load Bank
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
4
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
1
Load Bank
Turn all load bank switches Off. If
needed, connect load bank to 115
volts ac wall receptacle or genera-
tor auxiliary power receptacle.
2
Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3
Weld Cables
Connect load bank to generator
weld output terminals using proper
size weld cables with correct
connectors. Observe
polarity.
correct
Start engine and run for several
minutes.
3
Set load bank switches and then
adjust generator A/V control so
load equals rated voltage and
current of generator (see name-
plate, rating label, or the specifi-
cations section in this manual).
Check generator and load bank
meters after first five minutes then
every fifteen minutes to be sure
generatoris loaded properly.
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
ing run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then turn off load bank to
remove load. Run engine several
minutes at no load.
Y
Stop engine and let cool.
4
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0683
OM-4427 Page 55
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11-3. Run-In Procedure Using Resistance Grid
Y
Y
Stop engine.
Do not touch hot exhaust
pipe, engine parts, or load
bank/grid.
Y
Y
Keep exhaust and pipe away
from flammables.
6
Do not perform run-in
procedure at less than 20
volts weld output and do not
exceed duty cycle or equip-
ment damage may occur.
2
1
Resistance Grid
Use grid sized for generator rated
output.
1
Turn Off grid.
2
Welding Generator
Place A/V range switch in maxi-
mum position, A/V control in mini-
mum position, and Output Selector
switch (if present) in either DC
position.
3
Weld Cables
Connect grid to generator weld
output terminals using proper size
weld cables with correct connec-
tors (polarity is not important).
4
5
Voltmeter
Clamp-On Ammeter
Connect voltmeter and ammeter as
shown, if not provided on generator.
5
3
Start engine and run for several
minutes.
Set grid switches and then ad-
just generator A/V control so
load equals rated voltage and
current of the generator (see
nameplate, rating label, or the
specifications section in this
manual).
4
Check generator and meters after
first five minutes then every fifteen
minutes to be sure generator is
loaded properly.
+
.
C
h
e
c
k
o
i
l
l
e
v
e
l
f
r
e
q
u
e
n
t
l
y
d
u
r
-
ing run-in; add oil if needed.
It is recommended to run the weld-
ing generator for two hours mini-
mum and up to four hours under
load. Place A/V control in minimum
position, then shut down grid to
remove load. Run engine several
minutes at no load.
Y
Stop engine and let cool.
6
Engine Exhaust Pipe
Repeat procedure if wetstacking is
present.
S-0684
OM-4427 Page 56
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SECTION 12 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven
welding generators. Your unit may differ from those shown.
NOTE
12-1. Selecting Equipment
1
Generator Power Receptacles
− Neutral Bonded To Frame
2
3-Prong Plug From Case
Grounded Equipment
3
2-Prong Plug From Double
Insulated Equipment
Y
Do not use 2-prong plug un-
less equipment is double in-
sulated.
1
2
3
Be sure equipment
has this symbol
and/or wording.
OR
gen_pwr 11/02 − Ref. ST-159 730 / ST-800 577
12-2. Grounding Generator To Truck Or Trailer Frame
Y
Always ground generator
frame to vehicle frame to pre-
vent electric shock and static
electricity hazards.
1
2
3
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
1
Metal Vehicle Frame
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #10 AWG or larger
insulated copper wire.
2
GND/PE
Y
If unit does not have GFCI re-
ceptacles, use GFCI-pro-
tected extension cord.
3
Electrically bond generator
frame to vehicle frame by
metal-to-metalcontact.
Y
Bed liners, shipping skids, and some running
gear insulate the welding generator from the ve-
hicle frame. Always connect a ground wire from
the generator equipment grounding terminal to
bare metal on the vehicle frame as shown.
S-0854
OM-4427 Page 57
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12-3. Grounding When Supplying Building Systems
1
2
EquipmentGrounding
Terminal
1
2
Grounding Cable
GND/PE
Use #10 AWG or larger insulated
copper wire.
3
Ground Device
Y
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
Use ground device as stated
in electrical codes.
2
3
ST-800 576-B
12-4. How Much Power Does Equipment Require?
1
Resistive Load
3
A light bulb is a resistive load and
requires a constant amount of power.
VOLTS 115
AMPS 4.5
Hz 60
2
2
Non-Resistive Load
1
Equipment with a motor is a non-re-
sistive load and requires approxi-
mately six times more power while
starting the motor than when running
3
Rating Data
3
Rating shows volts and amperes, or
watts required to run equipment.
AMPERES x VOLTS = WATTS
EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power
requirementin watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520 watts.
EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1,
add the individual loads to calculate total load.
(200 W + 200 W + 200 W) + 520 W = 1120 W
The total load applied by the three flood lamps and drill is 1120 watts.
S-0623
OM-4427 Page 58
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12-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Rating
Starting Watts
Running Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
Capacitor Start-Induction Run
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
1-1/2 HP
2 HP
3 HP
5 HP
Capacitor Start-Capacitor Run
Fan Duty
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
550
650
800
1100
12-6. Approximate Power Requirements For Farm/Home Equipment
Farm/HomeEquipment
Stock Tank De-Icer
Rating
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
Grain Cleaner
1/4 HP
1/2 HP
3/4 HP
Portable Conveyor
Grain Elevator
1000
1400
1100
2800
720
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1-1/2 HP
2 HP
3 HP
5 HP
High Torque (e.g. Barn
1-1/2 HP
5 HP
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
1400
1600
800
Refrigerator or Freezer
Shallow Well Pump
1/3 HP
1/2 HP
1/3 HP
1/2 HP
750
1000
800
Sump Pump
1050
OM-4427 Page 59
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12-7. Approximate Power Requirements For Contractor Equipment
Contractor
Rating
Starting Watts
Running Watts
Hand Drill
1/4 in
3/8 in
350
400
350
400
1/2 in
600
600
Circular Saw
Table Saw
6-1/2 in
7-1/4 in
8-1/4 in
9 in
500
500
900
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
1400
1500
1800
1100
720
10 in
Band Saw
14 in
Bench Grinder
6 in
8 in
1400
1600
1000
1500
2200
2800
1100
1100
350
10 in
Air Compressor
1/2 HP
1 HP
1-1/2 HP
2 HP
Electric Chain Saw
Electric Trimmer
Electric Cultivator
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
500
500
2100
400
700
Elec. Hedge Trimmer
Flood Lights
18 in
400
HID
125
100
Metal Halide
Mercury
Sodium
Vapor
313
250
1000
1400
1250
600
1000
200
Submersible Pump
Centrifugal Pump
Floor Polisher
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
900
500
4500
6100
3150
4500
6100
1900
900
1400
1600
950
High Pressure Washer
3/4 HP
1400
1600
700
1 HP
55 gal Drum Mixer
Wet & Dry Vac
1/4 HP
1.7 HP
900
2-1/2 HP
1300
1300
OM-4427 Page 60
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12-8. Power Required To Start Motor
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
4
AC MOTOR
VOLTS 230 AMPS 2.5
Hz 60
PHASE 1
2
1
3
CODE
HP
M
1/4
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiplyrunning amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amper-
age (see example).
Welding generator amperage out-
put must be at least twice the
motor’s running amperage.
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
kVA/HP x HP x 1000
VOLTS
= STARTING AMPERAGE
EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4
HP motor with a motor start code of M.
Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2
11.2 x 1/4 x 1000
= 12.2 A
Starting the motor requires 12.2 amperes.
230
S-0624
12-9. How Much Power Can Generator Supply?
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to small-
est, and add resistive loads last.
2
5 Second Rule
1
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
2
Ref. ST-800 396-A / S-0625
OM-4427 Page 61
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12-10. Typical Connections To Supply Standby Power
Y
Properly install and ground this equipment according to
its Owner’s Manual and national, state, and local codes.
1
2
3
4
Fused
Disconnect
Switch
Utility
Electrical
Service
Welding
Generator
Output
Transfer Switch
(If Required)
5
Essential
Loads
Y
Y
Have only qualified persons perform Switch transfers the electrical load from Connect generator with temporary or perma-
these connections according to all electric utility service to the generator. Trans- nent wiring suitable for the installation.
applicable codes and safety practic- fer load back to electric utility when service is
Turn off or unplug all equipment connected to
generator before starting or stopping engine.
When starting or stopping, the engine has
low speed which causes low voltage and
frequency.
es.
restored.
Properly install and ground this Install correct switch (customer-supplied).
equipment according to its Owner’s Switch rating must be same as or greater
than the branch overcurrent protection.
Manual and national, state, and local
codes.
3 Fused Disconnect Switch
5 Essential Loads
. Customer-supplied equipment is re-
quired if generator will supply standby
power during emergencies or power out-
ages.
Install correct switch (customer-supplied) if
required by electrical code.
Generatoroutput may not meet the electrical
requirements of the premises. If generator
does not produce enough output to meet all
4 Welding Generator Output
Generator output voltage and wiring must be requirements, connect only essential loads
1 Utility Electrical Service
consistent with regular (utility) system volt- (pumps, freezers, heaters, etc. − See Sec-
2 Transfer Switch (Double-Throw)
age and wiring.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-4427 Page 62
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12-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
600
350 (106)
250 (76)
175 (53)
112 (34)
87 (26)
62 (19)
50 (15)
50 (15)
37 (11)
225 (68)
150 (46)
112 (34)
75 (23)
50 (15)
37 (11)
37 (11)
137 (42)
100 (30)
62 (19)
37 (11)
30 (9)
100 (30)
62 (19)
50 (15)
30 (9)
7
840
400 (122)
275 (84)
175 (53)
137 (42)
112 (34)
87 (26)
10
15
20
25
30
35
40
45
50
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 (91)
225 (68)
175 (53)
150 (46)
125 (38)
112 (34)
100 (30)
87 (26)
75 (23)
62 (19)
62 (19)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
Y
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
4
6
8
10
12
14
5
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
700 (213)
500 (152)
350 (107)
225 (69)
175 (53)
125 (38)
100 (31)
100 (31)
75 (23)
450 (137)
300 (91)
225 (69)
150 (46)
100 (31)
75 (23)
225 (84)
200 (61)
125 (38)
75 (23)
200 (61)
125 (38)
100 (31)
60 (18)
7
800 (244)
550 (168)
350 (107)
275 (84)
225 (69)
175 (53)
150 (46)
125 (38)
125 (38)
100 (31)
10
15
20
25
30
35
40
45
50
800 (244)
600 (183)
450 (137)
350 (107)
300 (91)
250 (76)
225 (69)
200 (61)
175 (53)
60 (18)
75 (23)
*Conductor size is based on maximum 2% voltage drop
OM-4427 Page 63
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SECTION 13 − PARTS LIST
127
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
40C Models
Only
24
23
22
6
7
19
8
21
20
25
27
5
4
18
12
26
9
3
10
11
2
13
17
28
14
15
16
1
29
30
31
32
111
112
113
109
110
118 (CV)
119 (CV)
117
Fig.
108
120
13−7
126
121
122
114 (Fig. 13-2
OR 13-3
107
115
106
123
116 (CC ONLY)
124
125 (Fig. 13-4 OR 13-5)
Figure 13-1. Main Assembly (Export Model Shown)
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39
38
40
54
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55
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41
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44
58
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93 (FIG. 13-6)
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96
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76
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91
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85
803 646-D
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 189 824 . . PANEL, gen LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . ♦199 294 . . PANEL, gen LH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . ♦+210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . 220539 . . LABEL, diesel engine maintenance (required on rh door only) . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . ♦199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . Z1 . . . CC214 972 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C
. . . 11 . . . . . Z1 . . . V214 964 . . REACTOR, ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 206 352 . . BRACE, front to center upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 203 260 . . LABEL, caution do not use ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . 1T . . . . 038 621 . . BLOCK, term 30A 4 pole frict term str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 038 620 . . . . LINK, jumper term blk 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . 081 499 . . BRACKET, mtg strip terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . SR4, SR5 . 035 704 . . RECTIFIER, integ bridge 40. amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 16 . . . . CB4 . . . 045 061 . . CIRCUIT BREAKER, auto reset 24vdc 7 amp . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . T1 . . . . 201 613 . . TRANSFORMER w/bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . T1 . . . ♦205 636 . . TRANSFORMER w/bracket (environmental coating) . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . 19 . . . . . . . . . . . . . 189 708 . . FIREWALL, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . 191 307 . . COVER, plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . 189 763 . . BRACKET, mtg air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 189 618 . . HOSE, air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 198 457 . . TUBE, air intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . 173 036 . . HOSE, elbow air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 010 863 . . . . CLAMP, hose 1.125 − 3.000 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 25 . . . . . . . . . . . . . 189 764 . . AIR CLEANER, intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 938 . . . . FILTER, air element primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . *♦192 939 . . . . FILTER, air element safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . 189 464 . . SEAL, weather lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od x 24.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . 191 819 . . HOSE, sae .312 id x .560 od x 14.000 (order by ft) . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . 198 584 . . HOSE, sae .312 id x .560 od x 5.000 (order by ft) . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 095 636 . . HOSE, sae .187 id x .41 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 206 297 . . BASE, fuel filter w/fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 192 741 . . . . BLOCK, spacer mtg filter base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . *192 744 . . FILTER, fuel spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 201 658 . . UPRIGHT, center assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 201 697 . . PAN, reactor and rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . +201 934 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . ♦+202 640 . . COVER, top ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 189 052 . . GROMMET, plastic neck filler fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 190 198 . . CAP, tank screw−on 3.500 in w/vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 192 041 . . LABEL, use diesel fuel only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 222 513 . . LABEL, warning falling equipment can cause serious . . . . . . . . . . . . . . . . . 2
. . . 38 . . . . . . . . . . . . . 224 265 . . LABEL, warning hot exhaust parts do not touch . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . 105 734 . . PIPE, muffler extension elbow 1.750 od . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 201 851 . . COVER, radiator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Figure 13-1. Main Assembly (Continued)
. . . 40 . . . . . . . . . . . . ♦202 629 . . COVER, radiator access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 191 354 . . SUPPORT, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . ♦202 633 . . SUPPORT, cover e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . 010 875 . . CLAMP, muffler 2.000 dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 203 180 . . MANIFOLD, exhaust muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 203 179 . . . . BRACKET, support muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 44 . . . . . . . . . . . . . 213 185 . . ENGINE, cat dsl elec 3024c series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *214 931 . . . . SENDER, coolant temp & 110c n.o. switch . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *215 094 . . . . SWITCH, oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 023 562 . . . . CLAMP, hose .312 − .875 clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197 899 . . . . FILTER, oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *192 744 . . . . FILTER, fuel spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . *197 997 . . . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 214 658 . . HOSE, radiator upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . *197 944 . . BELT, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 217 775 . . GUARD, belt (export models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . . . . . . . . . 202 017 . . GUARD, belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . 220 280 . . RADIATOR, w/shroud (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 220 281 . . . . SHROUD, radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 214 884 . . . . RADIATOR, w/14# cap 4 row core 3 pass . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 187 120 . . . . CAP, radiator pressure 14 lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 50 . . . . . . . . . . . . . 201 749 . . UPRIGHT, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . ♦207 188 . . UPRIGHT, rear ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . ♦207 005 . . GRILL, rear panel ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . 108 081 . . TERMINAL PROTECTOR, battery post mtg . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 52 . . . . . . . . . . . . . 190 206 . . CABLE, bat neg 42 in lg No. 2 awg w/clamp and .375rng . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . 190 207 . . CABLE, bat pos 45 in lg No. 1 awg w/clamp and .406rng . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . 203 430 . . BRACKET, battery holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 190 897 . . BATTERY, stor 12V 650crk 110rsv gp 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 168 385 . . LABEL, warning battery explosion can blind . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . +201 183 . . COVER, battery access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . ♦+202 639 . . COVER, battery access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . 201 006 . . BOLT, j stl .312−18 x 8.500 pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 60 . . . . . . . . . . . . +215 006 . . GUARD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . 197 496 . . HOSE, radiator lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 199 505 . . HOSE, oil drain assy 32 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . 165 271 . . . . VALVE, oil drain 3/8−18NPTF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . 176 529 . . . . FITTING, hose brs barbed fem 1/2tbg x 3/8NPT . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . 113 854 . . . . HOSE, SAE .500 ID x .780 OD xc oil (order by ft) . . . . . . . . . . . . . . . . . . 3ft
. . . 65 . . . . . . . . . . . . . 197 448 . . FITTING, hose brs barbed elbow m 1/2 tbg x 3/8 npt . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, oil drain (available through engine manufacturer) . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . 197 196 . . FITTING, adapter oil drain 12mm male x 3/8 npt female . . . . . . . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . 199 849 . . SCREW, 625−11 x 4.00hexhd pln gr 5 pld . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 69 . . . . . . . . . . . . . 071 731 . . WASHER, flat .656 ID x 2.250 OD x .187T stl pld . . . . . . . . . . . . . . . . . . . . 4
. . . 70 . . . . . . . . . . . . . 197 489 . . BRACKET, mtg RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . 197 488 . . BRACKET, mtg LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . 071 890 . . RETAINER, mount eng/gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 72 . . . . . . . . . . . . . 071 730 . . TUBING, stl .875 OD x 12ga wall x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 73 . . . . . . . . . . . . . 083 476 . . MOUNT, eng/gen nprn .875 ID x 2.500 OD x 2.000 . . . . . . . . . . . . . . . . . . 4
. . . 74 . . . . . . . . . . . . . 135 205 . . NUT, 625−11 .94hex .76H stl pld elastic stop nut . . . . . . . . . . . . . . . . . . . . . 4
. . . 75 . . . . . . . . . . . . . 190 992 . . KEEPER, latch engine access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 76 . . . . . . . . . . . . . 190 076 . . CHANNEL, stiffener engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 76 . . . . . . . . . . . . ♦202 635 . . CHANNEL, stiffener engine access e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Description
Quantity
Figure 13-1. Main Assembly (Continued)
. . . 77 . . . . . . . . . . . . . 191 626 . . BUMPER, door engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 78 . . . . . . . . . . . . . 199 592 . . LATCH, paddle series 20 (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 79 . . . . . . . . . . . . . 220 686 . . LABEL, diesel engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . . +200 989 . . DOOR, engine access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 80 . . . . . . . . . . . ♦+210 736 . . DOOR, engine access ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 81 . . . . . . . . . . . . . 218 002 . . LABEL, CAT diesel power 4.000 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 82 . . . . . . . . . . . . . 189 975 . . HINGE, door access 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 83 . . . . . . . . . . . . . 190 190 . . TANK, coolant recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . . 189 826 . . PANEL, rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 84 . . . . . . . . . . . . ♦199 298 . . PANEL, rocker ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 85 . . . . . . . . . . . . . 208 141 . . STOP, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . . 189 827 . . PANEL, gen RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 86 . . . . . . . . . . . . ♦199 300 . . PANEL, gen RH ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 87 . . . . . . . . . . . . . *197 997 . . FILTER, fuel secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 88 . . . . . . . . . . . . . 173 909 . . HOSE, sae .312 id x .560 od (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 89 . . . . . . . . . . . . . . . . . . . . . . . . PUMP, fuel (available through engine manufacturer) . . . . . . . . . . . . . . . . . 1
. . . 90 . . . . . . . . . . . . . 218 222 . . BRACKET, mtg fuel filter/pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 91 . . . . . . . . . . . . ♦198 624 . . IDLE SOLENOID ASSEMBLY (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 049 839 . . . . BRACKET, adjustment solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 080 517 . . . . SOLENOID, 12vdc pull type tubular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 203 716 . . . . BRACKET, mtg solenoid 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 605 277 . . . . PIN, cotter .093 x .750 zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 198 370 . . . . ROD, throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 206 209 . . . . BALL JOINT, .250−28 thd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 198 609 . . . . ARM, throttle 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 92 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 93 . . . . . . . . . . . Figure13-6 . . GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 94 . . . . . . . . . . . . . 218 087 . . TANK, fuel (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 95 . . . . . . . . . . . . . 189 909 . . . . FITTING, stand pipe hose .250 x 9.260 lg 90deg zinc . . . . . . . . . . . . . . . 1
. . . 96 . . . . . . . . . . . . . 095 636 . . . . HOSE, sae .187 id x .410 od x 30.000 (order by ft) . . . . . . . . . . . . . . . . . 1
. . . 97 . . . . . . . . . . . . . 201 025 . . . . CAP, fuel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 98 . . . . . . . . . . . . . 189 913 . . . . FITTING, stl barbed elbow zinc pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 99 . . . . . . . . . . . . . 190 142 . . . . SENDER, fuel gauge 9.7500 deep tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 100 . . . . . . . . . . . . 189 910 . . . . FITTING, stand pipe hose .3125 x 9.260 lg 90deg zinc . . . . . . . . . . . . . 1
. . 101 . . . . . . . . . . . . 181 572 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 102 . . . . . . . . . . . . 189 908 . . . . VALVE, drain fuel 180deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 103 . . . . . . . . . . . . 191 446 . . . . EXTRUSION, rubber w/adhesive 1.000 x 1.000 D (order by ft) . . . . . . . 6ft
. . 104 . . . . . . . . . . . . 124 253 . . . . BUSHING, tank fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . 084 173 . . . . CLAMP, hose .460 − .545clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 105 . . . . . . . . . . . . 189 912 . . . . FITTING, stl barbed elbow w/.047 in orf zinc pld . . . . . . . . . . . . . . . . . . . 1
. . 106 . . . . . . . . . . . . 224 266 . . LABEL, warning do not weld on base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 107 . . . . . . . . . . . . 191 897 . . BRACKET, mtg unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 108 . . . . . . . . . . . . 192 362 . . BRACKET, mtg nyl 1/2 conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 109 . . . . . . . . . . . . 196 220 . . BRACKET, hold down fuel tank rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . . +200 999 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 110 . . . . . . . . . . ♦+203 382 . . BASE e−coat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 111 . . . . . . . . . . . . 218 086 . . BRACKET, hold down fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 112 . . . . . . . . . . . . 173 352 . . EXTRUSION, rubber clamp/bulb (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . 113 . . . . . . . . . . . . 189 731 . . FIREWALL, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 114 . . . . . Figures 13-2, 13-3 CONTROL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 115 . . . . R3 . . . . 189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 116 . . . . R2 . . . CC189 699 . . RESISTOR, WW tap 375W 10 ohm w/mtg bkt . . . . . . . . . . . . . . . . . . . . . . 1
. . 117 . . . . . . . . . Figure 13-7 . . MAIN RECTIFIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C
. . 118 . . . PC1 . . V189 143 . . MODULE, field current regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
C
. . 119 . . . . . . . . . . . V193 453 . . BRACKET, mtg box fcr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 120 . . . . . . . . . . . . 191 448 . . TOP, cover front upright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Figure 13-1. Main Assembly (Continued)
. . 120 . . . . . . . . . . . ♦199 305 . . TOP, cover front upright ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 121 . . . . . . . . . . . . 212 944 . . LABEL, weld control/arc condition information label . . . . . . . . . . . . . . . . . . 1
. . 122 . . . . . . . . . . . . . . . . . . . . . . . Not Applicable
. . 123 . . . . . . . . . . . +201 750 . . UPRIGHT, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 123 . . . . . . . . . . ♦+202 637 . . UPRIGHT, front ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 124 . . . . . . . . . . . . 223 379 . . LABEL, warning general precautionary csa . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 125 . . . . . Figures 13-4, 13-5 PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 126 . . . CT1 . . ♦202 130 . . XFMR, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . . . +189 828 . . PANEL, engine side (40C Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 127 . . . . . . . . . . ♦+199 301 . . PANEL, engine side ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 190 058 . . NUT, .250−20 u−nut multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . 049 525 . . NUT, 312−18 u−nut multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . 215 627 . . KIT, label (includes safety & informational labels) (CC models) . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 215 629 . . KIT, label (includes safety & informational labels) (CC/CV models) . . . . . 1
. . . . . . . . . . . . . . . . . . . 216 985 . . KIT, label (includes safety & informational labels) (CC export models) . 1
. . . . . . . . . . . . . . . . . . . 216 984 . . KIT, label (includes safety & informational labels) (CC/CV export models)1
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
C
CC models only.
CC/CV models only.
C
C
V
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement
Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 69
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a
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a
r
e
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not available unless listed.
7
6
8
9
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4
10
11
13
3
12
2
1
14
15
16
17
24
23
18
19
20
21
22
803 647-E
Figure 13-2. Control Box Assembly − CC Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . CR7 . . . 188 636 . . RELAY, OCV control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . C12 . . . 191 944 . . CAPACITOR, polyp met film 10. uf 250 vac 10% . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . R6 . . . . 141 424 . . RESISTOR, ww fxd 30 w 25 ohm faston te . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . CR3 . . . 090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 1
. . . 9 . . . . CR8 . . . 197 325 . . RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CR1 . . . 090 104 . . RELAY, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CR6 . . ♦090104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 12 D10/C10, D11/C11 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . CB10 . . . 190 374 . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB14 . . ♦205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CR5 . . . 223 710 . . RELAY, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . SR1, SR2 . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 18 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 19 . . . . TD1 . . . 214 928 . . TIMER, delay on make/break open 30 sec 12vdc . . . . . . . . . . . . . . . . . . . . 1
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Part
No.
Description
Quantity
. . . 20 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . D1/C1 . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 CB11, 12, 13 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . . . 3
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 71
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4
5
6
7
3
8
9
10
11
2
1
12
13
15
16
23
14
17
22
18
19
20
21
803 648-E
Figure 13-3. Control Box Assembly − CC/CV Models
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . F1, F2 . . *085 874 . . FUSE, mintr cer slo-blo 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . 046 432 . . HOLDER, fuse mintr .250 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . 201 077 . . CONTROL BOX, lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 201 078 . . CONTROL BOX, rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . CR3 . . ♦090 104 . . RELAY, encl 12VDC SPST 30A/15VDC spin flange mtg . . . . . . . . . . . . . . 1
. . . 6 . . . . CR8 . . . 197 325 . . RELAY, encl 12vdc spst 70a 4pin flange mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . CR1 . . . 090 104 . . RELAY, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . CR6 . . ♦090 104 . . RELAY, encl 12vdc spst 30a/15vdc 5pin flange mtg . . . . . . . . . . . . . . . . . . 1
. . . 9 D10/C10, D11/C11 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . CB10 . . . 190 374 . . CIRCUIT BREAKER, auto reset 12VDC 40A . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB14 . . ♦205 927 . . CIRCUIT BREAKER, auto reset 12vdc 12 amp . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CR5 . . . 223 710 . . RELAY, encl 12vdc dpst−no 25a 6pin flange . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 201 079 . . COVER, control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . PC7 . . ♦195 706 . . MODULE, pull to idle, two output, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . SR1 . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . CR4 . . ♦113 247 . . RELAY, encl 12vdc dpdt 20a/120vac 8pin flange mtg . . . . . . . . . . . . . . . . 1
. . . 17 . . . . PC9 . . . 192 224 . . CIRCUIT CARD ASSY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 19 . . . . . C9 . . . . . 087 110 . . CAPACITOR, elctlt 240uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4427 Page 72
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 20 . . . . . . . . . . . . . 177 136 . . CLAMP, capacitor 1.375dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . D1/C1 . . 189 701 . . DIODE/CAPACITOR BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . TD1 . . . 214 928 . . TIMER, delay on make/break open 30 sec 12vdc . . . . . . . . . . . . . . . . . . . . 1
. . . 23 CB11, 12, 13 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC frict . . . . . . . . . . . . . . . . 3
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 73
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.
H
a
r
d
w
a
r
e
i
s
c
o
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m
o
n
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4
not available unless listed.
3
5
2
6
1
7
8
9
11
10
42
41
40
39
12
13
14
15
35
38
16
31
32
30
37
36
17
34
33
28
29
18
19
21
20
22
27
24
26
25
803 649
23
Figure 13-4. Panel, Front w/Components − CC Models
OM-4427 Page 74
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 215 070 . . PLATE SCREENED, ident control rating; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 215 014 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220 544 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 208 278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . 188 635 . . RHEOSTAT, WW 300W 34 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 7 . . . . . S6 . . . . . 011 622 . . SWITCH, tgl DPDT 15A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . . . 1
. . . 9 . . . . RC13 . . . 032 897 . . RECEPTACLE, twlk grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . S1 . . . . 212 436 . . SWITCH, ignition 4 position w/handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB2 . . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 3
. . . 14 . . . GFCI1 . . 151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . 147 632 . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB2 . . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 1
. . . 13 . . . . CB3 . . . 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . GFCI1 . . 151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only) . . 1
. . . 16 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts etc . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . +215 347 . . PANEL, gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215 405 . . PANEL, gen pwr ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . ♦+215 403 . . PANEL, gen pwr (export models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . S12 . . ♦220 491 . . SWITCH, polarity/ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 24 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 25 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 26 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . . . . . . . . . 201 045 . . COVER, receptacle twistlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . HM . . . . 210 424 . . METER, hour 12-24VDC 2.25dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . 217 084 . . GAUGE, Coolant Temp 0− 300 Deg F Electric . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . 217 083 . . GAUGE, Pressure Oil 0−100 Psi Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4427 Page 75
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 38 . . . . . . . . . . . . ♦164 873 . . VOLT METER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . ♦164 874 . . AMMETER, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . 019 602 . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . 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 Parts. Model and serial number required when ordering parts from your local distributor.
.
H
a
r
d
w
a
r
e
i
s
c
o
m
m
o
n
a
n
d
not available unless listed.
4
3
5
6
2
7
8
9
1
10
11
12
58
57
13
14
56
15
16
17
55
18
19
33
54
53
52
20
21
48
51
47
46
49
50
22
31
30
23
32
45
24
43
26
44
25
28
29
34
27
35
42
36
41
37
38
40
39
803 650
Figure 13-5. Panel, Front w/Components − CC/CV Models
OM-4427 Page 76
Download from Www.Somanuals.com. All Manuals Search And Download.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 215 158 . . PLATE SCREENED, ident control; when ordering this item,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . the nameplate should also be ordered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, screened (order by model and serial number) . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . 215 014 . . PANEL, engine/weld control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . ♦220 544 . . PANEL, engine/weld control ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . S3 . . . . 208 278 . . SWITCH, range/changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R1 . . . . . 193 118 . . POT, cp flat 1t 2w 1k ohm linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . S6 . . . . 193 234 . . SWITCH, rotary 6 position gold contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 197527 . . Guard, Circuit Breaker (For S6 - Not Included w/Harness) . . . . . . . . . . . . 1
. . . 7 . . . . . S5 . . . . . 011 609 . . SWITCH, tgl SPDT 15A 125VAC on-none-on spd term chr . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . 202 209 . . SPACER, nylon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . PC6 . . . 192 995 . . CIRCUIT CARD ASSY, connector/receptacle . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . CB5 . . . 139 266 . . CIRCUIT BREAKER, man reset 1p 15a 250vac frict . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . CB6 . . . 083 432 . . CIRCUIT BREAKER, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . S2 . . . . 021 467 . . SWITCH, tgl spst 3a 250v off−none−(on) spd term . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . S1 . . . . 212 436 . . SWITCH, ignition 4posn w/o handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . CB1 . . . 201 083 . . CIRCUIT BREAKER, man reset 2P 20 A, 250VAC . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 201 553 . . CLIP, circuit breaker retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 147 632 . . RECEPTACLE, tw lk grd 2P3W 30A 250V L6-30R . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB2 . . . 093 996 . . CIRCUIT BREAKER, man reset 1P 20A 250VAC frict . . . . . . . . . . . . . . . . 1
. . . 15 . . . . CB3 . . . 139 266 . . CIRCUIT BREAKER, man reset 1P 15A 250VAC . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . GFCI1 . . 151 981 . . RECEPTACLE, str dx grd 2P3W 15/20A 125V GFCI . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC1 . . . 176 355 . . RECEPTACLE, str 2p3w 16a 220v flange mtg (export models only) . . 1
. . . 18 . . . . RC5 . . ♦182 954 . . RCPT, str 3P4W 50A 125/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . ♦025 248 . . STAND-OFF, insul .250-20 x 1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . ♦604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . ♦197 527 . . GUARD, circuit breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . ♦197 363 . . TERMINAL, ring tng screw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 23 . . . . CB7 . . ♦214 926 . . CIRCUIT BREAKER, man reset 3p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +215 347 . . PANEL, generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . +215 403 . . PANEL, gen pwr (export models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . ♦215 406 . . PANEL, generator power ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . +♦215 363 . . PANEL, generator power (full kVA option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . ♦214 927 . . BOOT, circuit breaker 1 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . ♦197 508 . . PLUG, protective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . ♦077 440 . . BUSHING, conduit 1 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . 601 836 . . NUT, 250−20 .50hex .19h brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 29 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . 083 030 . . STUD, brs .250−20 x 1.750 w/hex collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CT2 . . ♦197 433 . . TRANSFORMER, current sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . 190 861 . . LABEL, warning electric shock and moving parts etc . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . ♦197 399 . . LABEL, warning 3 ph generator power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . 209 056 . . COVER, receptacle w/gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . 206 795 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . S12 . . ♦195 825 . . SWITCH, polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S12 . . ♦220 491 . . SWITCH, polarity/AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 201 125 . . PANEL, mtg terminal pwr output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . 199 303 . . PANEL, mtg terminal pwr output ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . PC4, PC5 . 189 744 . . CIRCUIT CARD ASSEMBLY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . . . . . . . . . 039 046 . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 180 735 . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-4427 Page 77
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Item
No.
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Mkgs.
Part
No.
Description
Quantity
. . . 38 . . . . . . . . . . . . . 134 201 . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 39 . . . . . . . . . . . . . 181 169 . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 40 . . . . . . . . . . . . . 186 621 . . BOOT, generic output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . . . . . . . . ♦059 773 . . HANDLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . ♦010 647 . . PIN, spring cs .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . 039 047 . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . ♦196 073 . . LABEL, do not switch while welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . 021 385 . . BOOT, toggle switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . 190 323 . . BOOT, circuit breaker clear hex nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . 170 391 . . CONN, circ ms protective cap size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . HM . . . . 210 424 . . METER, hour 12−24vdc (snap−in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . FUEL . . . 192 265 . . GAUGE, fuel elec switch w/o sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . ♦193 228 . . METER, Volt Dc 8− 18 Scale 2.250 In Black Face . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . ♦217 084 . . GAUGE, Coolant Temp 0− 300 Deg F Electric . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 197 798 . . SENDER, Coolant Temp 300 Deg F M16 X 1.5 . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . 217 083 . . GAUGE, Pressure Oil 0−100 Psi Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 193 230 . . SENDER, Pressure Oil 0− 100 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . ♦164 873 . . METER, amp ac/dc 0− 500 0−600 dc scale 2.5 in . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . ♦164 874 . . METER, volt ac/dc 0− 100 scale 2.5 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . 097 922 . . KNOB, pointer .875 dia x .250 ID w/set screws plstc . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . 189 161 . . HANDLE, switch range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . 010 647 . . PIN, spring CS .156 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . 097 924 . . KNOB, pointer 1.625 dia x .250 ID w/set scrws plstc . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 024 103 . . BLANK, snap-in nyl .750 mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 120 304 . . BLANK, snap−in nyl .250 mtg hole black . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
♦Optional
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 021 or Label Kit 201 061 (export models only).
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 78
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17
16
18
11
15
12
21
10
14
9
13
19
8
22
23
7
6
5
3
24
25
26
4
27
2
1
28
29
30
31
32
33
34
35
36
802 552-B
Figure 13-6. Generator
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . 132 053 . . SCREW, .375−16x1.50 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 2 . . . . . . . . . . . . . 183 387 . . WASHER, conical spring .406 ID x .875 OD pltd . . . . . . . . . . . . . . . . . . . . . 6
. . . 3 . . . . . . . . . . . . . . 195 911 . . ENDBELL, gen (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . 143 220 . . . . O-RING, 2.859 ID x .139CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . 201 099 . . STATOR, exciter/gen pwr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . +215 011 . . STATOR, weld assembly complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . +♦216 318 . . STATOR, weld assembly complete (full kVA option) . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . 225 120 . . LABEL, warning moving parts can cause injury . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . . . . . . . . . 190 197 . . GUARD, generator wire mesh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . 172 674 . . SPRING, ext .240 OD x .041 wire x 3.500pld . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . 039 207 . . BAFFLE, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . ROTOR . . 212 996 . . ROTOR, Generator Segmented Assy (Includes) . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . 210 824 . . . . ROTOR, Generator (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . 024 617 . . . . . . RING, Rtng Ext 1.375 Shaft X .050 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . 053 390 . . . . . . BEARING, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, Drive (Not Sold Separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 210 447 . . . . FAN, Rotor Assy Generator (Segmented) (includes) . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . 210 332 . . . . . . PLATE, Flex Hubmount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . 206 242 . . . . . . FAN, Rotor Segmented Assy Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . . . . . . . . . . 049 026 . . . . . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . 10
. . . 18 . . . . . . . . . . . . . 083 883 . . . . . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . 10
. . . 19 . . . . . . . . . . . . . 080 389 . . . . . . SCREW, 312−18x1.00 Hexwhd.66d Stl Pld Slffmg Tap−rw . . . . . . . . 8
. . . 20 . . . . . . . . . . . . . 197 487 . . . . FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-6. Generator (Continued)
. . . 21 . . . . . . . . . . . . . 197 486 . . ADAPTER, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 4
. . . 23 . . . . . . . . . . . . . 049 026 . . SCREW, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 24 . . . . . . . . . . . . . 191 579 . . COVER, starter hole /Continental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 195 560 . . GUARD, starter hole deutz 912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . 083 883 . . WASHER, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . . . . 172 555 . . SCREW, M10-1.5 x 50hexhd pln 8.8pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 27 . . . . . . . . . . . . . 602 159 . . SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw . . . . . . . . . . . . . 6
. . . 28 . . . . . . . . . . . . . 601 961 . . SCREW, .312-18 x 2.25hexhd pln gr 5pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . . . . . . 602 211 . . WASHER, lock .318 ID x 0.586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 30 . . . . . . . . . . . . . 139 341 . . WASHER, exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 31 . . . . . . . . . . . . . *190 823 . . BRUSH, contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 32 . . . . . . . . . . . . . 208 469 . . CLIP, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 33 . . . . . . . . . . . . . 189 142 . . BRUSHHOLDER ASSEMBLY, gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . 602 242 . . WASHER, flat .375IDx0.875odx.083t stl pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . . . . . 602 211 . . WASHER, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . 604 534 . . SCREW, .312−18x1.25 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . . 2
+
When ordering a component originally displaying a precautionary label, the label should also be ordered. Order
label individually or as part of Label Kit 202 021 or Label Kit 201 061 (export models only).
*Recommended Spare Parts.
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 80
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3
2
1
5
6
7
8
9
802 279-A
Figure 13-7. Main Rectifier Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . . . . . . . . SR3 . . . 215 909 . . RECTIFIER (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . SR3 . . . . . . . . . ♦ . . RECTIFIER, environmental (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . . . . 188 137 . . . . CONNECTION BOARD, rectifier AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . 188 517 . . . . BUS BAR, connection board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 3 . . . . . . . . . . . . . 188 135 . . . . ENCLOSURE, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . 134 201 . . . . STAND-OFF, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . PC3 . . . 215 755 . . . . CIRCUIT CARD ASSEMBLY, protection . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . 188 136 . . . . INSULATOR, heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . 7 . . . . . . . . . . . . . 188 493 . . . . HEAT SINK, rectifier al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . D3, D5, D7 037 956 . . . . DIODE, rect 275A 300V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 9 . D2, D4, D6 037 957 . . . . DIODE, rect 275A 300V RP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-4427 Page 81
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Some wiring harness components (switches, relays, circuit breakers) are also referenced
elsewhere in this parts list. Purchase components separately or as part of the associated
wiring harness.
Note
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
. . . . . . . . . . . . . . . . . . . . 215054 . . Harness, control box, CC weld control (includes) . . . . . . . . . . . . . . . . . 1
. . . . . . . . SR1, SR2 . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . D1/C1 . . . 189701 . . Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
CB11, CB12, CB13 . . 139266 . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . CR7 . . . . 188636 . . Relay, Ocv Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S6 . . . . . 011622 . . Switch, Tgl 3pdt 15a 125vac On−none−on Spd Term . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211292 . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211293 . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 164617 . . Clip, Wiring Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . S2 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . RC3 . . . . 158466 . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215377 . . Harness, control box, CV weld control (includes) . . . . . . . . . . . . . . . . . 1
CB11, CB12, CB13 . . 139266 . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . SR1 . . . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC4 . . . . 047483 . . Conn, Rect Univ 084 15p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . RC3 . . . . 158466 . . Conn, Rect Univ 084 12p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 135133 . . Conn, Rect Univ 084 9p/S 3row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 150316 . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . S6 . . . . . 193234 . . Switch, Rotary 6 Posn Gold Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . S5 . . . . . 011609 . . Switch, Tgl Spdt 15a 125vac On−none−on Spd Term Chr . . . . . . . . . . . . 1
. . . . . . . . . D1/C1 . . . 189701 . . Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 193183 . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . 196603 . . Seal, Switch 6 Position Rotary .250 Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 141450 . . Conn, Rect Metrmate 10skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 093995 . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 211292 . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 211293 . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215013 . . Harness, weld control CC (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187654 . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 215207 . . Harness, weld control CV (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . 114063 . . Conn, Rect Univ 084 4p/S 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG8 . . . . 193184 . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG13 . . . 147992 . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 158465 . . Conn, Rect Univ 084 12p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187654 . . Seal, Wire Univ 12p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196602 . . Plug, Cavity 18,30 Position Cinch Connector . . . . . . . . . . . . . . . . . . . . . . . 6
OM-4427 Page 82
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses (Continued)
. . . . . . . . . . . . . . . . . . . . 221376 . . Harness, engine control (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
D10/C10, D11/C11 . . . 189701 . . Diode/Capacitor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . CB10 . . . . 190374 . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CR1 . . . . 090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 148850 . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . 114062 . . Conn, Rect Univ 084 15p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 212116 . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . 212117 . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . CR8 . . . . 197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 192558 . . Harness, range switch (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC6 . . . . 148389 . . Conn,Rect Univ 084 4p/S 1row Rcpt Cable/Panel Lkg . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201109 . . Harness, receptacle auxiliary power (includes) . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC1 . . . . 147632 . . Rcpt, Tw Lk Grd 2p3w 30a 250v *L6−30r . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB2 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 201053 . . Harness, receptacle auxiliary power (export models) (includes) . . . 1
. . . . . . . . . GFCI1 . . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB3 . . . . 139266 . . Circuit Breaker, Man Reset 1p 15a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . CB2 . . . . 093996 . . Circuit Breaker, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 190259 . . Harness, brushholder (includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . 135134 . . Conn, Rect Univ 084 9p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 187651 . . Seal, Wire Univ 9p/S 3row . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-4427 Page 83
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Effective January 1, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
*
Induction Heating Coils and Blankets
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Canvas Covers
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1. 5 Years Parts — 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
*
*
*
*
Water Coolant Systems (Integrated)
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
3. 1 Year — Parts and Labor Unless Specified
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Process Controllers
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue® for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
*
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches
miller_warr 1/05
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2005 Miller Electric Mfg. Co. 10/05
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