Miller Electric Welding System Big Blue 300 User Manual

OM-4433

218 314P

2007−11

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

Big Blue 300 P

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-8. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3-2. Manufacture r ’s Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-1. Weld, Power, And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-2. Dimensions, Weights, And Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4-4. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4-6. AC Generator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-1. Installing Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-2. Mounting Welding Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5-3. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-4. Activating The Dry Charge Battery (If Applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-5. Connecting The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-6. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-7. Connecting T o Weld Output T e rminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-8. Selecting Weld Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-9. Connecting T o R emote 14 Receptacle RC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 6 − OPERATING WELDING GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-1. Front Panel Controls (See Section 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6-3. Process/Contactor Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6-4. Lift-Arc t Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6-5. Remote Voltage/Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

SECTION 7 − OPERATING AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7-1. Generator Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SECTION 8 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-2. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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TABLE OF CONTENTS

8-5. Servicing Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8-6. Adjusting Engine Speed On Standard Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8-8. Servicing Fuel And Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8-9. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

8-10. Checking Generator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8-1 1 . Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8-12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION 9 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

SECTION 10 − RUN-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

10-1. Wetstacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

10-2. Run-In Procedure Using Load Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

10-3. Run-In Procedure Using Resistance Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION 11 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

SECTION 12 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

WARRANTY

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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

rom_2007−04

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

NOTICE − Indicates statements not related to personal injury.

1-2. Arc Welding Hazards

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

groundedreceptacle outlet.

When making input connections, attach proper grounding conduc-

tor first − double-check connections.

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

Frequentlyinspect input power cord for damage or bare wiring —

replace cord immediately if damaged — bare wiring can kill.

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.

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 Standards listed in Section 1-7. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

If earth grounding of the workpiece is required, ground it directly

with a separate cable.

ELECTRIC SHOCK can kill.

Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

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 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 equip-

ment is a hazard.

Do not touch live electrical parts.

Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

Wear dry, hole-free insulating gloves and body protection.

Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

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.

Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

SIGNIFICANT DC VOLTAGE exists in inverters after stop-

ping engine.

Use AC output ONLY if required for the welding process.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

If AC output is required, use remote output control if present on

unit.

Additionalsafety precautions are required when any of the follow-

ing electrically 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 unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomaticDC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

FLYING METAL or DIRT can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

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).

Wear approved safety glasses with side shields even under your

welding helmet.

Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

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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).

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

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.

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 haz-

ards.

If ventilation is poor, wear an approved air-supplied respirator.

Do not use welder to thaw frozen pipes.

Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,

coatings, cleaners, and degreasers.

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, or

cadmiumplated 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.

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

NOISE can damage hearing.

Noise from some processes or equipment can dam-

age hearing.

BUILDUP OF GAS can injure or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use ap-

proved air-supplied respirator.

Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect Implanted

Medical Devices.

ARC RAYS can burn eyes and skin.

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

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.

ImplantedMedical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating

operations.

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).

Wear approved safety glasses with side shields under your

helmet.

Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pres-

sure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process, be

sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

WELDING can cause fire or explosion.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

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,

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder — explosion will result.

and hot equipment can cause fires and burns. Accidental contact of

electrodeto metal objects can cause sparks, explosion, overheating,

or fire. Check and be sure the area is safe before doing any welding.

Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

Turn face away from valve outlet when opening cylinder valve.

Do not weld where flying sparks can strike flammable material.

Protect yourself and others from flying sparks and hot metal.

Keep protective cap in place over valve except when cylinder is in

use or connected for use.

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

Watch for fire, and keep a fire extinguisher nearby.

Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

OM-4433 Page 2

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1-3. Engine Hazards

STEAM AND HOT COOLANT can burn.

BATTERY EXPLOSION can BLIND.

If possible, check coolant level when engine is

cold to avoid scalding.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

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.

If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

Disconnect negative (−) cable first and connect it last.

Wear safety glasses and gloves and put a rag over radiator cap.

Turn cap slightly and let pressure escape slowly before

completely removing cap.

FUEL can cause fire or explosion.

Stop engine and let it cool off before checking or

adding fuel.

Do not add fuel while smoking or if unit is near

any sparks or open flames.

Using a generator indoors CAN KILL

YOU IN MINUTES.

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.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Always keep nozzle in contact with tank when fueling.

NEVER use inside a home or garage, EVEN IF

doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and

vents.

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

BATTERY ACID can BURN SKIN and EYES.

Stop engine before installing or connecting unit.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

Have only qualified people remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

Keep hands, hair, loose clothing, and tools away from moving

parts.

ENGINE HEAT can cause fire.

Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

Do not locate unit on, over, or near combustible

surfaces or flammables.

Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

Keep exhaust and exhaust pipes way from

flammables.

Block flywheel so that it will not turn while working on generator

components.

HOT PARTS can cause severe burns.

Do not touch hot parts bare handed.

Allow cooling period before working on equip-

ment.

To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.

EXHAUST SPARKS can cause fire.

Do not let engine exhaust sparks cause fire.

Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

1-4. Compressed Air Hazards

TRAPPED AIR PRESSURE AND WHIPPING

HOSES can cause injury.

BREATHING COMPRESSED AIR can

cause serious injury or death.

Release air pressure from tools and system be-

fore servicing, adding or changing attach-

ments, or opening compressor oil drain or oil fill

cap.

Do not use compressed air for breathing.

Use only for cutting, gouging, and tools.

COMPRESSED AIR can cause injury.

Wear approved safety goggles.

Do not direct air stream toward self or others.

OM-4433 Page 3

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HOT METAL from air arc cutting and

gouging can cause fire or explosion.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Stop engine and release air pressure before

servicing.

Use only genuine replacement parts from the

manufacturer.

Do not cut or gouge near flammables.

Watch for fire; keep extinguisher nearby.

HOT PARTS can cause burns and injury.

Do not touch hot compressor or air system

parts.

Let system cool down before touching or ser-

vicing.

1-5. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

WELDING WIRE can cause injury.

Do not install or place unit on, over, or near

combustiblesurfaces.

Do not press gun trigger until instructed to do

so.

Do not install unit near flammables.

Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

OVERUSE can cause OVERHEATING.

Use lifting eye to lift unit and properly installed

accessories only, NOT gas cylinders. Do not

exceed maximum lift eye weight rating (see

Specifications).

Lift and support unit only with proper equipment

and correct procedures.

Allow cooling period; follow rated duty cycle.

Reduce current or reduce duty cycle before

starting to weld again.

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.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE handling

boards or parts.

OVERHEATING can damage motors.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

Turn off or unplug equipment before starting or

stopping engine.

Do not let low voltage and frequency caused by

low engine speed damage electric motors.

TILTING OF TRAILER can cause injury.

Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle

where applicable.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

FLYING SPARKS can cause injury.

Wear a face shield to protect eyes and face.

Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

READ INSTRUCTIONS.

Read Owner’s Manual before using or servic-

ing unit.

Use only genuine replacement parts from the

manufacturer.

Perform engine and air compressor mainte-

nance and service according to this manual

and the engine/air compressor (if applicable)

manuals.

Sparks can cause fires — keep flammables away.

MOVING PARTS can cause injury.

Keep away from moving parts.

Keep away from pinch points such as drive

rolls.

OM-4433 Page 4

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H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communicationsequipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

Electromagnetic energy can interfere with

sensitive electronic equipment such as micro-

processors, computers, and computer-driven

equipmentsuch as robots.

Be sure all equipment in the welding area is

electromagneticallycompatible.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

If notified by the FCC about interference, stop using the

equipmentat once.

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Have the installation regularly checked and maintained.

Be sure this welding machine is installed and grounded

according to this manual.

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.

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.

1-6. California Proposition 65 Warnings

For Gasoline Engines:

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.)

Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproduc-

tive harm.

For Diesel Engines:

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.

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).

Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto

416-747-4044,website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd 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, Quincy, MA 02269-9101 (phone: 617-770-3000, web-

site: www.nfpa.org.

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).

NationalElectrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:

617-770-3000,website: www.nfpa.org and www. sparky.org).

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-

intendentof Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 Regional Offices—phone for

Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 4221 Walney Road, 5th Floor,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

CanadianStandards Association, Standards Sales, 5060 Mississauga,

1-8. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

1. Keep cables close together by twisting or taping them, or using a

cable cover.

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.

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.

About Implanted Medical Devices:

ImplantedMedical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

To reduce magnetic fields in the workplace, use the following

procedures:

OM-4433 Page 5

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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom_2007−04fre

Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.

2-1. Signification des symboles

DANGER! − Indique une situation dangereuse qui si on

l’évite pas peut donner la mort ou des blessures graves.

Les dangers possibles sont montrés par les symboles

joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas

peut donner la mort ou des blessures graves. Les dan-

gers possibles sont montrés par les symboles joints ou

sont expliqués dans le texte.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER

DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES

CHAUDES. Consulter les symboles et les instructions ci-dessous y

afférant pour les actions nécessaires afin d’éviter le danger.

NOTE − Indique des déclarations pas en relation avec des blessures

personnelles.

2-2. Dangers relatifs au soudage à l’arc

manuelAC avec tension à vide réduite. Dans la plupart des cas, un

poste courant continu de type CV est recommandé. Et, ne pas tra-

vailler seul!

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).

Installer et mettre à la terre correctement cet appareil conformé-

ment 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.

En effectuant les raccordements d’entrée fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques chau-

des.

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est

pas endommagé ou dénudé − remplacer le cordon immédiatement

s’il est endommagé − un câble dénudé peut provoquer une électro-

cution.

Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les ris-

ques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées à la section 2-7. Veuillez lire et respecter

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

particulièrementles enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquerune 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 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.

Mettre l’appareil hors tension quand on ne l’utilise pas.

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

Ne pas enrouler les câbles autour du corps.

Ne jamais toucher les pièces électriques sous tension.

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.

Porter des gants et des vêtements de protection secs ne compor-

tant pas de trous.

Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou-

blée.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer

sur-le-champ les pièces endommagées. Entretenir l’appareil

conformémentà ce manuel.

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.

S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants 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 humides, dans les endroits confinés ou là où on risque de

tomber.

Se servir d’une source électrique à courant électrique UNIQUE-

MENT 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 environnements à risque comme: les endroits humides ou

lorsque l’on porte des vêtements mouillés; sur des structures mé-

talliques au sol, grillages et échafaudages; 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

Une tension DC importante subsiste à l’intérieur

des onduleurs après avoir coupé l’alimentation.

Couper l’alimentation du poste et décharger les condensateurs

d’entrée comme indiqué dans la Section Maintenance avant de

toucher des composants.

OM-4433 Page 6

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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).

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements

et les étincelles ; prévenir toute personne sur les lieux de ne pas

regarder l’arc.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de

protection.

DES PIECES DE METAL ou DES SA-

LETES peuvent provoquer des bles-

sures dans les yeux.

LE SOUDAGE peut provoquer un in

cendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tel

que des réservoirs, tambours ou des conduites peu

provoquer leur éclatement. Des étincelles peuven

Le soudage, l’écaillement, le passage de la pièce à la brosse en

fil de fer, et le meulage génèrent des étincelles et des particules

métalliquesvolantes. Pendant la période de refroidissement des

soudures, elles risquent de projeter du laitier.

être projetées de l’arc de soudure. La projection d’étincelles, des pièce

chaudes et des équipements chauds peut provoquer des incendies e

des brûlures. Le contact accidentel de l’électrode avec des objet

métalliquespeut provoquer des étincelles, une explosion, un surchauf

fement ou un incendie. Avant de commencer le soudage, vérifier e

s’assurer que l’endroit ne présente pas de danger.

Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent être

dangereux.

Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir

soigneusementavec des protections homologués.

Le soudage génère des fumées et des gaz. Leur

inhalationpeut être dangereux pour votre santé.

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.

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.

Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites

fissures et des ouvertures.

Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les

consommables, les revêtements, les nettoyants et les dégraisseurs.

Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

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 déplacer 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 danger.

Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été

préparés correctement conformément à AWS F4.1 (voir les nor-

mes de sécurité).

Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

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 provo-

quant des risques d’électrocution, d’étincelles et d’incendie.

Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et

les rayons de l’arc peuvent réagir en présence de vapeurs et for-

mer 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 revête-

ment n’ait été enlevé dans la zone de soudure, que l’endroit soit

bien ventilé, et en portant un respirateur à alimentation d’air. Les

revêtementset tous les métaux renfermant ces éléments peuvent

dégager des fumées toxiques en cas de soudage.

Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

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 chaussures hautes et un couvre chef.

LES ACCUMULATIONS DE GAZ ris

quent de provoquer des blessures ou

même la mort.

Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

Une fois le travail achevé, assurez−vous qu’il ne reste aucune tra-

ce d’étincelles incandescentes ni de flammes.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateurd’adduction d’air homologué.

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.

LES RAYONS DE L’ARC peuvent pro

voquer des brûlures dans les yeux e

sur la peau.

LE BRUIT peut affecter l’ouïe.

Le rayonnement de l’arc du procédé de soudage

génère des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure

dans les yeux et sur la peau. Des étincelles sont projetées pendant le

soudage.

Le bruit des processus et des équipements peut affec

l’ouïe.

Porter des protections approuvés pour les ore

les si le niveau sonore est trop élevé.

OM-4433 Page 7

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Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou

de se renverser.

LES CHAMPS MAGNETIQUES peuv-

ent affecter des implants médicaux.

Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

Porteur de simulateur cardiaque ou autre im-

plants médicaux, rester à distance.

Ne jamais placer une torche de soudage sur une bouteille à gaz.

Les porteurs d’implants doivent d’abord consulter leur médecin

avant de s’approcher des opérations de soudage à l’arc, de sou-

dage par points, de gougeage, du coupage plasma ou de chauf-

fage par induction.

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 raccords convenables pour cette application spécifique;

les maintenir ainsi que les éléments associés en bon état.

Si des BOUTEILLES sont endomma

gées, elles pourront exploser.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

Des bouteilles de gaz protecteur contiennent du ga

sous haute pression. Si une bouteille est endomma

Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisationou de branchement de la bouteille.

gée, elle peut exploser. Du fait que les bouteilles de gaz fon

normalement partie du procédé de soudage, les manipuler ave

précaution.

Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

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.

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) mentionné dans les principales normes de sécurité.

2-3. Dangers existant en relation avec le moteur

Seules des personnes qualifiées sont autorisées à enlever les por-

tes, panneaux, recouvrements ou dispositifs de protection pour

effectuer, s’il y a lieu, des travaux d’entretien et de dépannage.

L’EXPLOSION DE LA BATTERIE peu

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants

en caoutchouc et vêtements de protection lors

d’une intervention sur la batterie.

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.

Arrêter le moteur avant de débrancher ou de brancher les câbles

de batterie.

Remettreen 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.

Eviter de provoquer des étincelles avec les outils en travaillant sur

la batterie.

Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la

mise en route accidentelle du moteur.

Ne pas utiliser le poste de soudage pour charger les batteries ou

des véhicules de démarrage rapide.

Bloquerle volant moteur pour éviter sa rotation lors d’une interven-

tion sur le générateur.

Observer la polarité correcte (+ et −) sur les batteries.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Débrancher le câble négatif (–) en premier lieu. Le rebrancher en

dernier lieu.

Ne pas toucher à mains nues les parties chau-

des.

Prévoir une période de refroidissement avant de

travailler à l’équipement.

LE CARBURANT MOTEUR peut provo

quer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau de

carburant ou de faire le plein.

Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

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.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

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.

Il est préférable de vérifier le liquide de refroi-

dissementune fois le moteur refroidi pour éviter

de se brûler.

Toujours garder le pistolet en contact avec le réservoir lors du

remplissage.

Toujours vérifier le niveau de liquide de refroidissement dans le

vase d’expansion (si présent), et non dans le radiateur (sauf si pré-

cisé autrement dans la section maintenance du manuel du

moteur).

DES ORGANES MOBILES peuvent pro

voquer des blessures.

Si le moteur est chaud et que le liquide doit être vérifié, opérer com-

me suivant.

Ne pas approcher les mains des ventilateurs,

courroies et autres pièces en mouvement.

Mettre des lunettes de sécurité et des gants, placer un torchon sur

le bouchon du radiateur.

Maintenirfermés et fixement en place les portes, panneaux, re-

couvrements et dispositifs de protection.

Dévisser le bouchon légèrement et laisser la vapeur s’échapper

avant d’enlever le bouchon.

Arrêter le moteur avant d’installer ou brancher l’appareil.

OM-4433 Page 8

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L’utilisation d’un groupe autonome

à l’intérieur PEUT VOUS TUER EN

QUELQUES MINUTES.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

Ne pas placer l’appareil sur, au-dessus ou à

proximité de surfaces inflammables.

Les fumées d’un groupe autonome contient du

monoxyde de carbone. C’est un poison invisi-

ble et inodore.

Tenir à distance les produits inflammables de l’échappement.

JAMAIS utiliser dans une maison ou garage,

même avec les portes et fenêtres ouvertes.

Uniquementutiliser à l’EXTERIEUR, loin des portes, fenêtres et

bouches aération.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Empêcher les étincelles d’échappement du

moteur de provoquer un incendie.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

Utiliser uniquement un pare-étincelles

approuvé − voir codes en vigueur.

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.

Ne pas couper ou gouger à proximité de pro-

duits inflammables.

Surveillez et garder un extincteur à proximité.

Ne pas utiliser l’air comprimé pour respirer.

Utiliser l’air comprimé seulement pour le cou-

page, gougeage et les outils pneumatiques.

DES PIECES CHAUDES peuvent provo-

quer des brûlures et blessures.

L’AIR COMPRIMÉ peut provoquer

des blessures.

Ne pas toucher le compresseur ou d’autres

éléments du circuit air comprimé chauds.

Porter des lunettes de sécurité approuvées.

Ne pas diriger le jet d’air vers d’autres ou

soi-même.

Laisser l’ensemble se refroidir avant de toucher ou d’effectuer la

maintenance.

L’AIR COMPRIME EMMAGASINE ET DES

TUYAUX SOUS PRESSION peuvent provo-

quer des blessures.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

Relâcher la pression d’air de l’outillage ou du

système avant d’effectuer la maintenance,

avant de changer ou de rajouter des éléments

ou avant d’ouvrir la purge ou le bouchon de

remplissaged’huile.

Arrêter le moteur et relâcher la pression avant

d’effectuer la maintenance.

N’utiliser que les pièces de rechange recommandées par le

constructeur.

2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU D’EXPLO-

SION.

LA CHUTE DE L’APPAREIL peut blesser.

Utiliser l’anneau de levage pour lever l’appareil et

les accessoires correctement installées seuls,

PAS les bouteilles de gaz. Ne pas dépasser le

poids nominal maximal de l’œilleton (voir les spé-

cifications).

Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

Ne pas installer l’appareil à proximité de pro-

duits inflammables.

Ne lever et ne soutenir l’appareil qu’avec de

l’équipement approprié et en suivant les

procédures adéquates.

Ne pas surcharger l’installation électrique − s’assurer que l’ali-

mentationest correctement dimensionnée et protégée avant de

mettre l’appareil en service.

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.

OM-4433 Page 9

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UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Utiliser les supports de la remorque ou des

blocs pour soutenir le poids.

Arrêter ou déconnecter l’équipement avant de

démarrer ou d’arrêter le moteur.

Installer convenablement le poste sur la remor-

que comme indiqué dans le manuel s’y rappor-

tant.

Ne pas laisser tourner le moteur trop lentement sous risque d’en-

dommagerle moteur électrique à cause d’une tension et d’une fré-

quence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,

s’il y a lieu.

LIRE LES INSTRUCTIONS.

Lisez le manuel d’instructions avant l’utilisation

ou la maintenance de l’appareil.

N’utiliser que les pièces de rechange recom-

mandées par le constructeur.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Effectuer la maintenance et le service du moteur et du compres-

seur d’air suivant les instructions dans ce manuel ou le manuel

du moteur/compresseur (si applicable).

Porter un écran facial pour protéger le visage et

les yeux.

Affûter l’électrode au tungstène uniquement à la

meuleuse dotée de protecteurs. Cette manœuv-

re est à exécuter dans un endroit sûr lorsque l’on

porte l’équipement homologué de protection du

visage, des mains et du corps.

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipe-

ments de radio−navigation et de communica-

tion, les services de sécurité et les ordinateurs.

Les étincelles risquent de causer un incendie − éloigner toute sub-

stance inflammable.

Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal-

lation.

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas s’approcher des organes mobiles.

Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

L’utilisateurest tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

Effectuer régulièrement le contrôle et l’entretien de l’installation.

LES FILS DE SOUDAGE peuvent

provoquer des blessures.

Maintenirsoigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une dis-

tance correcte et utiliser une terre et un blindage pour réduire les

interférences éventuelles.

Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

Ne pas diriger le pistolet vers soi, d’autres per-

sonnes ou toute pièce mécanique en enga-

geant le fil de soudage.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provo-

quer des interférences pour l’équipement élec-

tronique sensible tel que les ordinateurs et

l’équipementcommandé par ordinateur tel que

les robots.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le fac-

teur de marche nominal.

Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

Veiller à ce que tout l’équipement de la zone de soudage soit

compatibleélectromagnétiquement.

Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser

aussi bas que possible (ex. par terre).

Ne pas obstruer les passages d’air du poste.

Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les

circuits imprimés.

Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé-

mentairestelles que le déplacement du poste, l’utilisation de câ-

bles blindés, l’utilisation de filtres de ligne ou la pose de protec-

teurs dans la zone de travail.

Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

Utiliser des pochettes et des boîtes antistatiques pour stocker,

déplacer ou expédier des cartes de circuits imprimes.

OM-4433 Page 10

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2-6. Proposition californienne 65 Avertissements

Pour les moteurs à essence :

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 mal-

formations congénitales et, dans certains cas, des cancers.

(Code de santé et de sécurité de Californie, chapitre 25249.5

et suivants)

Les gaz d’échappement des moteurs contiennent des pro-

duits chimiques dont l’État de Californie reconnaît qu’ils

provoquent des cancers et des malformations congénitales

ou autres problèmes de procréation.

Pour les moteurs diesel :

Les batteries, les bornes et autres accessoires contiennent

du plomb et des composés à base de plomb, produits chimi-

ques dont l’État de Californie reconnaît qu’ils provoquent des

cancers et des malformations congénitales ou autres

problèmesde procréation. Se laver les mains après manipu-

lation.

Les gaz d’échappement des moteurs diesel et certains de

leurs composants sont reconnus par l’État de Californie com-

me provoquant des cancers et des malformations

congénitalesou autres problèmes de procréation.

2-7. Principales normes de sécurité

Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,

de Global Engineering Documents (téléphone : 1-877-413-5184, site

Internet : www.global.ihs.com).

L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site

Internet : www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, de American National Standards Institute,

11 West 43rd Street, New York, NY 10036-8002 (téléphone :

212-642-4900,site Internet : www.ansi.org).

RecommendedSafe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1 de Global Engineering Documents (téléphone

1-877-413-5184,site Internet : 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, Quincy, MA 02269-9101 (téléphone : 617-770-3000,

site Internet : www.nfpa.org).

National Electrical Code, NFPA Standard 70, de National Fire Protec-

tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (téléphone :

617-770-3000, site Internet : www.nfpa.org).

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, de U.S. Government Printing Office, Superin-

tendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(téléphone: 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-

ne de la région 5, Chicago, est 312-353-2220, site Internet :

www.osha.gov).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-

tilly, VA 20151 (téléphone

www.cganet.com).

703-788-2700, site Internet

Code for Safety in Welding and Cutting, CSA Standard W117.2, de

CanadianStandards Association, 5060 Mississauga, Ontario, Canada

2-8. Information EMF

Considérationssur le soudage et les effets de basse fréquence et des

champs magnétiques et électriques.

1. Garder les câbles ensemble, les torsader, les scotcher, ou les

recouvrir d’une housse.

2. Disposer les câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir exa-

miné 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

magnétiqueset champs électriques 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

souhaitablede réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

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

soudure.

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant

de s’approcher des opérations de soudage à l’arc, de soudage par

points, de gougeage, du coupage plasma ou de chauffage par induc-

tion. Si le médecin approuve, il est recommandé de suivre les

procédures précédentes.

Pour réduire les champs magnétiques sur le poste de travail, appliquer

les procédures suivantes :

OM-4433 Page 11

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SECTION 3 − DEFINITIONS

3-1. Warning Label Definitions

Remove unit from shipping

crate. Remove Owner’s

Manual from unit. Follow

instructions to install muffler.

S-177 571

Read Owner’s Manual. Read

labels on unit.

Use Diesel Fuel only, and fill

fuel tank. Leave room for

expansion.

Warning! Watch Out! There

are possible hazards as

shown by the symbols. Read

Owner’s Manual. Follow

instructions to activate

battery.

DIESEL

Check oil level. Add oil if

necessary.

During the first 50 hours of

operation, keep welding load

above 200 amperes. Do not

weld below 200 amperes of

output.

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

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 12

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3-2. Manufacturer’s Rating Label

228 417-B / 803 562-F

OM-4433 Page 13

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3-3. Symbols And Definitions

Fast (Run, Weld/

Power)

Stop Engine

Slow (Idle)

Start Engine

Engine Oil

Starting Aid

(Preheat)

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

Read Operator’s

Manual

Do Not Switch

While Welding

Three Phase

Circuit Protector

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Electrode

Connection

Work Connection

Hertz

Rated No Load

Conventional

Load Voltage

Rated Load

Speed

Duty Cycle

U₀

n₀

U₂

Voltage (Average)

I₂

Rated Idle

Speed

Rated No Load

Speed

Rated Welding

Current

n₁

Contactor On

Arc Force (Dig)

Lift-Arc TIG

OM-4433 Page 14

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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

Perkins

Circuit

Voltage

400 A, 23 Volts DC,

40% Duty Cycle

300 A, 32 Volts DC

60% Duty Cycle

20 − 410 A

(CC Models)

CC/DC

250 A, 30 Volts DC

100% Duty cycle

Single-Phase,

10 kVA/kW, 84/42 A,

120/240 V AC,

60 Hz

Perkins 403C-15

Water-Cooled,

11.5 gal

(43.5 L)

400 A, 23 Volts DC,

30% Duty Cycle

Three-Cylinder,

CV/DC

(CC/CV

Models

Only)

21.7 HP Diesel Engine

300 A, 29 Volts DC

60% Duty Cycle

14 − 40 V

250 A, 26.5 Volts DC

100% Duty cycle

4-2. Dimensions, Weights, And Operating Angles

Dimensions

32 in (813 mm)

35-3/4 in (908 mm)

(to top of lift eye)

Height

Width

26-1/4 in (667 mm)

(mtg. brackets turned in)

Do not exceed tilt angles or engine could

be damaged or unit could tip.

28-3/4 in (730 mm)

(mtg. brackets turned out)

Do not move or operate unit where it

could tip.

Depth

56 in (1422 mm)

54 in (1372 mm)

52 in in (1321 mm)

2 in (51 mm)

26 in (660 mm)

7/8 in (22 mm)

30°

27-3/4 in (705 mm)

20°

9/16 in (14 mm) Dia.

4 Holes

Front Panel End

Weight

No fuel: 1100 lb (499 kg)

w/ fuel: 1199 lb (544 kg)

Lifting Eye Weight Rating:

1500 lb (680 Kg) Maximum

OM-4433 Page 15

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4-3. Volt-Ampere Curves

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

MIN

300

MAX

100

200

300

400

500

DC AMPERES

B. MIG Mode

100

200

300

DC AMPERES

C. TIG Mode

100

MIN

300

MAX

300

200

DC AMPERES

217 517 / 217 516 / 217 518

OM-4433 Page 16

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4-4. Fuel Consumption

The curve shows typical fuel use

under weld or power loads.

2.00

1.75

1.50

1.25

1.00

0.75

0.50

IDLE

0.25

0.00

100 150 200 250 300 350 400

DC WELD AMPERES AT 100% DUTY CYCLE

217 509

4-5. Duty Cycle And Overheating

100% Duty Cycle

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

250 amperes continuously.

NOTICE − Exceeding duty cycle

can damage unit and void warranty.

1000

800

600

500

400

300

250

200

150

100

20 25 30

% DUTY CYCLE

40 50 60

100

217 515

OM-4433 Page 17

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4-6. 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

160

AC AMPERES IN 240 V MODE

120

AC AMPERES IN 120 V MODE

217 519

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

16 Gauge (.063 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4433 Page 18

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SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Always securely fasten weld-

ing generator onto transport

vehicle or trailer and comply

with all DOT and other applica-

ble codes.

Movement

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.

NOTICE − Do not install unit where

air flow is restricted or engine may

overheat.

Location/AirflowClearance

rating.

information.

Grounding:

Equipment Grounding Terminal

(On Front Panel)

Grounding Cable (Not Supplied)

Metal Vehicle Frame

. Electrically bond generator

frame to vehicle frame by met-

al-to-metalcontact.

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger insu-

lated copper wire.

18 in

(460 mm)

18 in

Bed liners, shipping skids,

and some running gears insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equipment

grounding terminal to bare

metal on the vehicle frame as

shown.

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm)

Grounding

GND/PE

install3 2007−04 − Ref. 800 652 / Ref. 800 477-A / 803 274 / 804 712

OM-4433 Page 19

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5-2. Mounting Welding Generator

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

NOTICE − Do not mount unit by

supportingthe base only at the four

mounting brackets. Use cross-

supports to adequately support unit

and prevent damage to base.

Mounting Surface:

Cross-Supports

Mounting Brackets (Supplied)

Mount unit on flat surface or use

cross-supports to support base.

Secure unit with mounting brack-

ets.

1/2 in Bolt And Washer

(Minimum − Not Supplied)

Inadequate support.

3/8-16 x 1 in Screws

(Supplied)

To Bolt Unit In Place:

Do not use flexible mounts.

Remove hardware securing the

four mounting brackets to the base.

Reverse brackets and reattach to

base with original hardware.

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.

Welding Unit In Place

Bolting Unit In Place

Tools Needed:

9/16 in

install3 2007−04 803 274 / 200 864-A / 803 562

OM-4433 Page 20

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5-3. Installing Exhaust Pipe

Stop engine and let cool.

. Point exhaust pipe in desired di-

rection but always away from front

panel and direction of travel.

Tools Needed:

1/2 in

803 582 / Ref. 217 357-A

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 21

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5-4. Activating The Dry Charge Battery (If Applicable)

Always wear a face shield,

rubber gloves and protective

clothing when working on a

battery.

Remove battery from unit.

Vent Caps

Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

Well

Fill each cell with electrolyte to

bottom of well (maximum).

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.

Battery Charger

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.

. When electrolyte is low, add

only distilled water to cells to

maintainproper level.

5 A For 30 Minutes

−

30 A For 12 Minutes

Tools Needed:

drybatt1 6/05 − S-0886

5-5. Connecting The Battery

Connect Negative (−) Cable Last.

−

Tools Needed:

1/2 in

803 563 / Ref. 217 357-A / S-0756-C

OM-4433 Page 22

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5-6. Engine Prestart Checks

Check radiator coolant

level when fluid is low in

recovery tank.

Full

Diesel

Capacity:

6 qt (5.7 L)

Coolant Recovery Tank

Hot Full

Cold Full

Full

803 563

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).

NOTICE − Incorrect engine temperature

can damage engine. Do not run engine with-

out a properly working thermostat and ra-

diator 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

pipe during run-in, see Section 10.

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.

Use Preheat switch (see Section 6-1).

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

NOTICE − 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

expansion.

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

(see Section 8-2).

OM-4433 Page 23

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5-7. Connecting To Weld Output Terminals

Stick and TIG Welding

MIG and FCAW Welding

For Stick and TIG welding Direct Current Elec-

For MIG and FCAW welding Direct Current

ElectrodePositive (DCEP) connect wire feed-

er cable to CV (Wire) terminal on right and

work cable to Work/Negative (−) terminal on

left. Use Process/Contactor switch to select

type of weld output (see Section 6-3).

trode Positive (DCEP), connect electrode

holder cable to CC (Stick/TIG) terminal on

right and work cable to Work/Negative (−) ter-

minal on left.

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

For Direct Current Electrode Negative

(DCEN), reverse cable connections.

Use Process/Contactor switch to select type

of weld output (see Section 6-3).

Stop engine.

Work/Negative (−) Weld Output Terminal

CV (wire) Weld Output Terminal

CC (Stick/TIG) Weld Output Terminal

Failure to properly connect weld

cables may cause excessive heat and

start a fire, or damage your machine.

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.

Tools Needed:

3/4 in

Do not place

anything between

weld cable terminal

and copper bar.

Correct Installation

Incorrect Installation

803 562 / 803 778-A

OM-4433 Page 24

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5-8. Selecting Weld Cable Sizes*

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

Weld Output

Terminals

Stop engine before

connecting to weld

output terminals.

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)

Do not use worn, dam-

aged, undersized, or

poorly spliced cables.

10 − 60% 60 − 100%

Welding

Amperes

Duty

10 − 100% Duty Cycle

Cycle

100

150

200

4 (20)

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)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2/0 (70)

3/0 (95) 4/0 (120)

(2x70)

2 ea. 2/0 2 ea. 3/0 2 ea. 3/0

(2x70) (2x95) (2x95)

1/0 (60)

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)

2/0 (70)

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)

* This 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.

( ) = 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.

Notes

OM-4433 Page 25

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5-9. Connecting To Remote 14 Receptacle RC14

Socket*

Socket Information

24 volts ac. Protected by sup-

plementary protector CB8.

24 VOLTS AC

Contact closure to A completes

24 volt ac contactor control

circuit.

Output to remote control:+10

volts dc in MIG mode; 0 to +10

volts dc in Stick or TIG mode.

Remote control circuit common.

REMOTE

OUTPUT

CONTROL

DC input command signal: 0 to

+10 volts from min. to max. of

remote control with Voltage/

Amperage Adjust control at

max.

LDR-14 long

distance remote

(includes 120 V

receptacle)

115 volts, 10 amperes, 60 Hz

ac. Protected by supplementary

protector CB7.

115 VOLTS AC

Contact closure to I completes

115 volt ac contactor control

circuit.

Current feedback: 1 volt per

100 amperes.

Voltage feedback: 1 volt per 10

arc volts.

Chassis common.

GND

803 562

NEUTRAL

Circuit common for 24 and 115

volt ac circuit.

*The remaining sockets are not used.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 26

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Notes

Welding Symbols

Ref. AWS/ANSI A2.4

OM-4433 Page 27

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SECTION 6 − OPERATING WELDING GENERATOR

6-1. Front Panel Controls (See Section 6-2)

217 357-B / 803 563

OM-4433 Page 28

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6-2. Description Of Front Panel Controls (See Section 6-1)

Engine Starting Controls

Preheat Switch

Engine Gauges, Meters, And Lights

Fuel Gauge/Hourmeter

Process/Contactor Switch

See Section 6-3 for Process/Contactor

switch information.

Use gauge to check fuel level or total engine

operating hours.

Use switch to energize starting aid for cold

weather starting (see starting instructions fol-

lowing).

Voltage/Amperage Control

To check fuel level or engine hours when en-

gine is not running, turn Engine Control switch

to Run or Auto (optional) position.

With Process/Contactor switch in any Stick or

TIG setting, use control to adjust amperage.

With Process/Contactor switch in any Wire

(MIG) position, use control to adjust voltage.

With Voltage/Amperage Adjust Switch in Re-

mote position, control limits the remote am-

peragein Stick or TIG mode, but has no effect

in Wire (MIG) modes.

Engine Control Switch

Use switch to start engine, select engine

speed (if unit has auto idle option), and stop

engine.

Engine Indicator Light

Light goes on and engine stops if engine tem-

perature exceeds 230° F (110° C) or engine

oil pressure is below 10 psi (69 kPa).

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.

Weld Meters

F (82 - 955 C). Normal oil pressure is 30

- 60 psi (207 - 414 kPa).

. Weld meters also work in combination to

display troubleshooting help codes (see

Section 8-1 1).

Engine Stop Lever

NOTICE − Do not run engine until trouble is

fixed.

Use lever to stop engine if Engine Control

switch does not work.

Weld Controls

DC Voltmeter

. The Engine Stop lever shuts off the fuel

supply. However, the Engine Stop lever

will not stop the engine if the engine can

draw fuel-rich air from the surrounding

atmosphere(oil refineries).

Remote Control Receptacle

Voltmeterdisplays preset voltage (MIG weld-

ing) with contactor off, and actual output volt-

age with the contactor on. Voltmeter displays

voltage at the weld output terminals, but not

necessarily the welding arc due to resistance

of cable and connections.

Use receptacle to connect remote controls,

wire feeders, and tools.

When a remote control is connected to the

Remote receptacle, the Auto Sense Remote

feature automatically switches voltage/am-

peragecontrol to the remote control (see Sec-

tion 5-9).

To Start:

To set voltage, turn contactor off and turn Pro-

cess/Contactor switch to Wire position. Turn

V/A control until desired voltage is displayed

on Voltmeter. When welding is finished, volt-

meter displays weld voltage and then defaults

to preset voltage.

NOTICE − Do not use ether.

With remote control connected, weld output is

determined by a combination of front panel

and remote control voltage/amperage set-

tings.

. If engine does not start, let engine come

to a complete stop before attempting re-

start.

Above 325 F (05 C): turn Engine Control

switch to Start. Release Engine Control

switch when engine starts.

10 DC Ammeter

If no remote control is connected to the Re-

mote receptacle, the front panel Voltage/Am-

perage control adjusts voltage and amper-

age.

Ammeter displays preset amperage (Stick

and TIG only) when not welding, and actual

output amperage when welding.

Below 325 F (05 C): turn engine control switch

to Auto position. Push Preheat switch up for

60 seconds. Turn Engine Control switch to

Start. Release Engine Control switch and

Preheat switch when engine starts.

To set amperage, turn Process/Contactor

Receptacle RC14 is faulty or is discon- switch to Stick or TIG position. Turn V/A con-

nected, the meters display Help 25 (see trol until desired amperage is displayed on

Section8-1 1). Clear fault by stopping and Ammeter. When welding is finished, ammeter

restarting the unit or by turning Process/ displays weld amperage and then defaults to

To Stop: turn Engine Control switch to Off

position.

Contactor switch to another position.

preset amperage.

OM-4433 Page 29

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6-3. Process/Contactor Switch

Process/Contactor Switch

Weld output terminals are ener-

gized when Process/Contactor

switch is in a Weld Terminals Al-

ways On position and the engine

is running.

Use switch to select weld process and

weld output on/off control (see table be-

low).

Place switch in Remote On/Off Switch

Requiredpositions 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 mode for air carbon arc

(CAC-A) cutting and gouging.

When switch is in Stick mode, select one

of four arc drive (dig) settings to provide

additionalamperage during low voltage

(short arc length) conditions and prevent

“sticking” electrodes. Turn control from A

to D to increase arc drive (dig) from min

to max.

Use the Lift-Arc TIG mode for TIG

(GTAW) welding using the Lift-Arc TIG

starting procedure (see Section 6-4).

803 562 / 217 357

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

GTAW With HF Unit, Pulsing

Device, Or Remote Control

At Remote 14 Receptacle

Active

Remote On/Off Switch

Stick (SMAW) With Remote On/Off

At Remote 14 Receptacle

Electrode Hot

Active

Required − Stick

Remote On/Off Switch

Required − CV Feeder

Using Remote

MIG (GMAW)

w/Constant Speed Feeder

Weld Terminals Always On −

MIG (GMAW)

w/Voltage Sensing Feeder

Wire

Stick (SMAW),

Air Carbon Arc (CAC-A) Cutting

And Gouging

Weld Terminals Always On −

Electrode Hot

Stick

Weld Terminals Always On −

TIG Lift-Arc (GTAW)

Electrode Hot

TIG Lift-Arc

OM-4433 Page 30

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6-4. Lift-Arc™ Start Procedure

Lift-Arc t TIG

With Lift-Arct TIG selected, start

arc as follows:

TIG Electrode

Workpiece

Lift-Arc Start Method

Turn gas on. Touch tungsten

electrodeto workpiece at weld start

point.

Hold

electrode

workpiece for 1-2 seconds, and

slowly lift electrode. Arc is formed

when electrode is lifted.

Normal open-circuit voltage is not

present before tungsten electrode

touches workpiece; only a low

sensing voltage is present between

electrode and workpiece. The

solid-state output contactor does

not energize until after electrode is

touching workpiece. This allows

electrode to touch workpiece

without overheating, sticking, or be-

ing contaminated.

1 − 2

“Touch”

Seconds

Application:

Lift-Arc is used for the DCEN

GTAW process when HF Start

method is not permitted, or to

replace the scratch method.

Do NOT Strike Like A Match!

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

OM-4433 Page 31

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6-5. Remote Voltage/Amperage Control

Remote 14 Receptacle RC14

Connect optional remote control to RC14 (see

Section 5-9).

Remote receptacle, the Auto Sense Re-

mote feature automatically switches volt-

age/amperage control to the remote con-

trol. When a device is connected to the Re-

mote receptacle, remote voltage/amper-

age control is always available regardless

of the position of the Process/Contactor

switch.

In Example:

Min = 20 A DC

Max = 205 A DC

Set V/A Control

Connect Remote

Control To Remote

Receptacle RC14

To Desired Maximum

Adjust Optional Remote

Weld Output Using Weld

Meters

Control to 100%

Set TIG or STICK Process

Max (205 A DC)

Min (20 A DC)

Adjust Optional Remote

Control to desired

weld output

Weld meters will always

show the combined main

and remote control setting

and machine welds at

nominal output setting of

the meter.

Adjust Optional Remote

Control to desired

weld output

Connect Remote

Control To Remote

Receptacle RC14

Weld meters show preset

output when not welding.

Set WIRE Process

0774 / Ref.217 357−B / 803 562

OM-4433 Page 32

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SECTION 7 − OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Receptacles

217 357-A

120 V 20 A AC (shown)

overload. If CB5 opens, the receptacles do

not work. Place CB5 switch in On position

to reset circuit breaker.

. At least once a month, run engine at

weld/power speed and press test but-

ton to verify GFCI is working properly.

Receptacle RC5 and/or GFCI1

120 V 20 A AC GFCI (shown)

Receptacle RC6 and/or GFCI2

. If a supplementary protector continues

to open, contact Factory Authorized

Service Agent.

RC11 supplies 60 Hz single-phase power

at weld/power speed. Maximum output

from RC11 is 10 kVA/kW.

240 V 50 A AC

Receptacle RC11

RC5 / 6 and GFCI1 / 2 supply 60 Hz single-

phase power at weld/power speed. Recep-

tacle configuration varies depending on

machine model and serial number.

Supplementary Protector CB4

Supplementary Protector CB6

Supplementary Protector CB5

output increases.

Combined output of all receptacles is limit-

ed to the 10 kVA/kw rating of the generator.

Maximumoutput from these receptacles is

2.4 kVA/kW.

CB4 protects RC6 / GFCI2 and CB6 pro-

tects RC5 / GFCI1 from overload. If a sup-

plementaryprotector opens, the receptacle

does not work. Press button to reset.

EXAMPLE: If 15 A is drawn from each 120

V receptacle , only 26 A is available at the

240 V receptacle:

If a ground fault is detected, GFCI Reset

button pops out and receptacle does not

work. Check for faulty equipment plugged

in receptacle. Press button to reset GFCI

receptacle.

Supplementary protector CB5 protects re-

ceptacles and the generator winding from

2 x (120 V x 15 A) + (240 V x 26 A) =

10.0 kVA/kW

OM-4433 Page 33

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SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Stop engine before maintaining.

. See Engine Manual and Maintenance Label

for important start-up, service, and storage

information. Service engine more often if

used in severe conditions.

Recycle engine

fluids.

Reference

* To be done by Factory Authorized Service Agent

Every

Hours

Section 5-6,

8-8

Every

Hours

Every

100

Hours

Section 8-3

Air Cleaner Element

Every

250

Hours

Engine

Manual,

Section 8-4

1/2 in.

(13 mm)

Spark Arrestor

Every

500

Hours

Radiator Thermostat

FUEL

Every

1000

Hours

Section 5-6,

8-10, 8-8

and Engine

Manual

SLUDGE

~ Drain Sludge

Radiator Fluid Level

Valve Clearance*

Brushes*

Every

2000

Hours

OM-4433 Page 34

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8-2. Maintenance Label

OM-4433 Page 35

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8-3. Servicing Air Cleaner

Stop engine.

NOTICE − Do not run engine without air

cleaner or with dirty element. Engine

damagecaused by using a damaged ele-

ment is not covered by the warranty.

. The air cleaner primary element can

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

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.

Housing

Keep nozzle

2 in (51 mm)

from element.

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

NOTICE − 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 2/01− ST-153 929-B / ST-153 585 / Ref. S-0698-B / Ref. 217 357-A

OM-4433 Page 36

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8-4. Inspecting And Cleaning Optional Spark Arrestor Muffler

Stop engine and let cool.

Spark Arrestor Muffler

Cleanout Plug

Tools Needed:

3/8 in

Remove plug and remove any dirt

covering cleanout hole.

Exhaust Pipe

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.

Stop engine and let cool.

Reinstall cleanout plug.

803 582 / Ref. 214 778-B

8-5. Servicing Engine Cooling System

Stop engine and let cool.

Radiator Draincock

Radiator Cap Cover

Change coolant according to engine

manual. Add coolant according to Sec-

tion 5-6).

Run engine until engine reaches normal

operating temperature. Check coolant

level in recovery tank. Add coolant if nec-

essary.

After engine cools, check coolant level

again and add coolant if necessary.

803 563

OM-4433 Page 37

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8-6. Adjusting Engine Speed On Standard Models

Stop engine and let cool.

Engine speed is factory set and

should not require adjustment. Af-

ter tuning engine, check engine

speed with tachometer or frequen-

cy meter. See table for proper no

load speed. If necessary, adjust

speed as follows:

Engine Speed

RPM (Hz)

(No Load)

1880 (61.7)

Maximum

Weld/Power

Start engine and run until warm.

Turn Process/Contactor switch to

Weld Terminals Always On − Stick

position.

Lock Nut

Adjustment Screw

Loosen nut. Turn screw until engine

runs at weld/power speed. Tighten

nut.

. Do not set engine speed higher

than specified. Tampering with

adjustments other than shown

may affect engine warranty

Engine Stop Lever

Stop engine.

Close door.

Tools Needed:

803 563-E

OM-4433 Page 38

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8-7. Adjusting Engine Speed On Models With Automatic Idle (Optional)

Engine Speed Adjustment

Engine Speed

(No Load)

After tuning engine, check en-

gine speed with tachometer or

frequency meter. See table for

proper no load speed. If neces-

sary, adjust speed as follows:

1880 rpm max

(62.6 Hz)

1500 rpm

(50 Hz)

Start engine and run until warm.

Turn Process/Contactor switch

to Stick − Weld Terminals Al-

ways On position.

Throttle Rod / Plunger

Lock Nut

Rubber Boot

Adjustment Screw

Adjustmentscrew is not used to

adjust engine speed when auto-

matic idle option is installed.

However, it must be at least 1/8

in (3 mm) away from the throttle

arm when engine is running at

idle rpm.

Unhook rubber boot from the so-

lenoid housing but leave con-

nected to plunger.

Loosen lock nut. Place Engine

Control Switch in Auto position.

Turn throttle rod and plunger un-

til engine runs at idle speed.

Tighten lock nut.

Hook rubber boot back onto so-

lenoid housing.

. Be sure solenoid plunger

pulls all the way in (“bot-

toms”) when energized.

Weld/Power Speed

Adjustment

. Weld/power speed adjust-

ment must be done by the

engine manufacturer’s fac-

tory authorized service

agent.

Tamperingwith adjustments

other than shown may affect

engine warranty.

Stop engine.

. To prevent solenoid

damage, be sure a 1/8

in (3 mm) gap exists be-

tween the engine low

speed

screw

and

throttle lever when the

solenoid is held in the

energizedposition.

803 563-G

OM-4433 Page 39

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8-8. Servicing Fuel And Lubrication Systems

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.

Oil Filter

Oil Drain Valve And Hose

Oil Fill Cap

Primary (Canister) Fuel Filter

Secondary (In-Line) 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.

To replace primary (canister) 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.

Inspect fuel lines, and replace if

cracked or worn.

To drain water from fuel system:

See engine manual.

To replace secondary (in-line)

fuel filter:

Note direction of fuel flow as indi-

cated by arrow on side of filter. Re-

move fuel line clamps and discon-

nect fuel lines from fuel filter. Re-

place filter, reconnect fuel lines, and

reinstall clamps.

To drain sludge from fuel tank:

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.

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-4433 Page 40

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8-9. Overload Protection

Stop engine.

mentary protector, or fuse

opens, it usually indicates a

more serious problem exists.

Contact Factory Authorized

Service Agent.

Fuse F1

F1 protects the stator exciter wind-

ing from overload. If F1 opens, weld

and generator power is low or stops

entirely.

Circuit Breaker CB1 (Not

Shown)

Supplementary Protector CB2

Supplementary Protector CB3

Supplementary Protector CB7

Supplementary Protector CB8

Circuit Breaker CB9

CB1 protects the engine battery cir-

cuit. If CB1 opens, the engine will not

crank. CB1 automatically resets

when the fault is corrected.

CB2 protects the engine wiring har-

ness. If CB2 opens, the engine will

not crank.

CB3 protects part of the weld control

wiring harness. If CB3 opens, weld

and generator power output stops.

CB7 protects the 115 volt ac output

to remote receptacle RC14. If CB7

opens, 115 volt output to RC14

stops.

CB8 protects the 24 volt ac output to

remote receptacle RC14. If CB8

opens, 24 volt output to RC14 stops.

Press button to reset supplementary

protector.

CB9 protects the throttle solenoid

against overload. If CB9 opens, the

engine does not automatically idle

down. Check the linkage and sole-

noid. CB9 automatically resets.

803 562 / 803 566

OM-4433 Page 41

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8-10. Checking Generator Brushes

Stop engine and let cool.

Generator Brush With Spring

Mark and disconnect leads at brush hold-

er cap. Remove brushes.

Replace brushes if damaged or if brush

materialis at or near minimum length.

5/16 in. (8 mm)

Minimum Length

9/16 in. (14.3 mm)

New Length

Replace

Damaged Brushes

Ref 2114 778−D / S−0233−A

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

16 Gauge (.063 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4433 Page 42

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8-11. Voltmeter/Ammeter Help Displays

Use the Voltmeter/Ammeter help

displays to diagnose and correct

fault conditions.

. When a help code is displayed

normally weld output has

stopped but generator power

output may be okay.

HL.P

. To reset help displays, stop

unit and then restart. See item

6 below to reset Help 25 dis-

play.

HL.P

Help 20 Display

Indicates a failure of meter display

modulePC2, or the wiring between

PC2 and main control module PC1.

If this display is shown, have Facto-

ry Authorized Service Agent check

PC1, PC2, and the wiring between

PC1 and PC2.

HL.P

Help 21 Display

Indicates thermistor TH1 on the

main rectifier heat sink has failed.

If this display is shown, have Facto-

ry Authorized Service Agent check

TH1, and the wiring between TH1

and PC1.

HL.P

Help 22 Display

Indicates the rectifier heat sink has

overheated.If this display is shown,

check generator cooling system

and/or reduce duty cycle. Keep en-

gine access door closed when run-

ning to maintain proper cooling air

flow past rectifier. Allow unit to cool

before restarting. If problem contin-

ues, have Factory Authorized Ser-

vice Agent check unit.

HL.P

Help 23 Display

Indicates one of the rectifier output

SCR’s has failed. If this display is

shown, have Factory Authorized

Service Agent check the rectifier

SCR’s.

Help 24 Display

Indicates weld open circuit voltage

(OCV) is too high (above 41 volts

dc). If this display is shown, have

Factory Authorized Service Agent

check main control module PC1.

Help 25 Display

Indicates a remote device con-

nected to Remote Receptacle

RC14 may be faulty. Help 25 is also

displayed whenever a remote de-

vice has been connected to RC14

and then disconnected. Clear fault

by stopping and restarting the unit

or by turning Process/Contactor

switch to another position. If prob-

lem continues, have Factory Autho-

rized Service Agent check the re-

mote device, filter board PC6, and

main control module PC1.

803 562 / 217 357-A

OM-4433 Page 43

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8-12. Troubleshooting

(

)

A. Welding

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 turn remote contactor on (see Section 5-9).

Reset supplementary protector CB7 or CB8 (see Section 8-9). Check for faulty remote device connected

to RC14.

Check and secure connections to Remote Control receptacle RC14 (see Section 5-9).

Check Voltmeter/Ammeter help displays (see Section 8-11).

No weld output, or generator power out- Disconnect equipment from generator power receptacles during start-up.

put at ac receptacles.

Reset supplementary protector CB3. (see Section 8-9).

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the voltage regulator module PC3.

Check Voltmeter/Ammeter help displays (see Section 8-11).

Have Factory Authorized Service Agent check brushes and slip rings, voltage regulator module PC3, and

field excitation circuit.

Erratic weld output.

Check and tighten connections inside and outside unit.

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.

Have Factory Authorized Service Agent check main control module PC1 and hall device HD1.

Check engine speed, and adjust if necessary.

High weld output.

Low weld output.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the rotor.

Low open-circuit voltage.

Check engine speed, and adjust if necessary.

Have Factory Authorized Service Agent check main control module PC1, voltage regulator module PC3,

and main rectifier.

No remote fine amperage control.

Repair or replace remote control device.

Check and secure connections to Remote Amperage Adjust receptacle RC14 (see Section 5-9).

No 24 volt or 115 volt ac output at Re- Reset supplementary protector CB7 (24 volt) or CB8 (115 volt) (see Section 8-9).

mote receptacle RC14.

OM-4433 Page 44

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B. Generator Power

Trouble

Remedy

No generator power output at ac recep- Reset receptacle supplementary protector(s) (see Section 7-1).

tacles; weld output okay.

No generator power or weld output.

Disconnect equipment from generator power receptacles during start-up.

Check fuse F1, and replace if open (see Section 8-9). Have Factory Authorized Service Agent check vol-

tage regulator module PC3.

Reset supplementary protector CB3 (see Section 8-9).

Check Voltmeter/Ammeter help displays (see Section 8-11).

Have Factory Authorized Service Agent check brushes and slip rings, and field excitation circuit.

High output at generator power ac re- Have Factory Authorized Service Agent check voltage regulator module PC3.

ceptacles.

Low output at generator power ac recep- Check engine speed, and adjust if necessary.

tacles.

Check fuse F1, and replace if open (see Section 8-9). If F1 is open, have Factory Authorized Service

Agent check the rotor.

C. Engine

Trouble

Remedy

Engine will not crank.

Check battery, and replace if necessary.

Check battery connections and tighten if necessary.

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9).

Have Factory Authorized Service Agent check engine wiring harness and components.

Reset supplementary protector CB2 (see Section 8-9).

Check engine wiring harness plug connections.

Have Factory Authorized Service Agent check Engine Control switch S1, and control relay CR2.

Check fuel level.

Engine cranks but does not start.

Engine hard to start in cold weather.

Check battery and replace if necessary. Check engine charging system according to engine manual.

Have Factory Authorized Service Agent check control relay CR1, fuel solenoid FS1, and the fuel

pump.

Air in fuel system. See engine manual.

Use Preheat switch (see Section 6-1).

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.

Use correct grade oil for cold weather (see Section 8-2).

Have Factory Authorized Service Agent check Preheat switch S4, control relay CR3, and the glow

plug.

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 5-6 ).

Circuit breaker CB1 may be open. CB1 automatically resets when fault is corrected (see Section 8-9).

Reset supplementary protector CB2 (see Section 8-9). Have Factory Authorized Service Agent check

engine alternator, engine harness, throttle solenoid TS1, fuel solenoid FS1, and the fuel pump.

Have Factory Authorized Service Agent check Engine Control switch S1, control relay CR1, inte-

grated rectifier SR2, fuel solenoid FS1, and the fuel pump.

See engine manual.

OM-4433 Page 45

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Trouble

Remedy

Engine slowly stopped and cannot be

restarted.

Check fuel level.

Check engine air and fuel filters (see Sections 8-3 and 8-8).

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 PC5 and current transformer CT1.

Engine idles, but does not come up to

weld speed (units with idle option only).

Check for obstructed throttle solenoid.

Engine does not run at idle speed

(units with idle option only).

Circuit breaker CB9 may be open. CB9 automatically resets when fault is corrected (see Section 8-9).

Have Factory Authorized Service Agent check idle module PC5, and control relay CR4.

Engine uses oil during run-in period; Dry engine according to run-in procedure (see Section 10).

wetstacking occurs.

Notes

OM-4433 Page 46

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Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in)

22 Gauge (.031 in)

20 Gauge (.037 in)

18 Gauge (.050 in)

16 Gauge (.063 in)

14 Gauge (.078 in)

1/8 in (.125 in)

3/16 in (.188 in)

1/4 in (.25 in)

5/16 in (.313 in)

3/8 in (.375 in)

1/2 in (.5 in)

OM-4433 Page 47

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SECTION 9 − ELECTRICAL DIAGRAMS

Figure 9-1. Circuit Diagram For Welding Generator

OM-4433 Page 48

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219 228−E

OM-4433 Page 49

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SECTION 10 − RUN-IN PROCEDURE

run_in1 2007−04

10-1. Wetstacking

NOTICE − Do not perform run-in

procedure at less than 20 volts

weld output and do not exceed duty

cycle or equipment damage may

occur.

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.

NOTICE− Do not idle engine longer

than necessary. Piston rings seat

faster if engine runs at weld/power

rpm, and the welding generator is

kept loaded during run-in.

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-4433 Page 50

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10-2. Run-In Procedure Using Load Bank

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in

procedureat less than 20 volts weld

output and do not exceed duty

cycle or equipment damage may

occur.

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.

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.

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.

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.

NOTICE − Check oil level frequent-

ly during 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.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0683

OM-4433 Page 51

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10-3. Run-In Procedure Using Resistance Grid

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

NOTICE − Do not perform run-in

procedureat less than 20 volts weld

output and do not exceed duty

cycle or equipment damage may

occur.

Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

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.

Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

Voltmeter

Clamp-On Ammeter

Connect voltmeter and ammeter as

shown, if not provided on generator.

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).

Check generator and meters after

first five minutes then every fifteen

minutes to be sure generator is

loaded properly.

NOTICE − Check oil level frequent-

ly during 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.

Stop engine and let cool.

Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

S-0684

OM-4433 Page 52

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SECTION 11 − 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.

11-1. Selecting Equipment

Generator Power Receptacles

− Neutral Bonded To Frame

3-Prong Plug From Case

Grounded Equipment

2-Prong Plug From Double

Insulated Equipment

. Be sure equipment has double

insulated symbol and/or word-

ing on it.

Do not use 2-prong plug un-

less equipment is double in-

sulated.

gen_pwr 2007−04 − Ref. ST-159 730 / ST-800 577

11-2. Grounding Generator To Truck Or Trailer Frame

Always ground generator

frame to vehicle frame to pre-

vent electric shock and static

electricity hazards.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

EquipmentGrounding

Terminal (On Front Panel)

Grounding Cable (Not

Supplied)

Metal Vehicle Frame

GND/PE

Connect cable from equipment

ground terminal to metal vehicle

frame. Use #10 AWG or larger

insulated copper wire.

. Electrically bond generator

frame to vehicle frame by met-

al-to-metal contact.

Bed liners, shipping skids,

and some running gear insu-

late the welding generator

from the vehicle frame. Al-

ways connect a ground wire

from the generator equip-

ment grounding terminal to

bare metal on the vehicle

frame as shown.

If unit does not have GFCI re-

ceptacles, use GFCI-pro-

tected extension cord.

S-0854

OM-4433 Page 53

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11-3. Grounding When Supplying Building Systems

EquipmentGrounding

Terminal

Grounding Cable

GND/PE

Use #10 AWG or larger insulated

copper wire.

Ground Device

electrical codes.

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

Also see AWS Safety

Health Fact Sheet No. 29,

Grounding of Portable And

Vehicle Mounted Welding

Generators.

ST-800 576-B

11-4. How Much Power Does Equipment Require?

Resistive Load

A light bulb is a resistive load and

requires a constant amount of power.

Non-Resistive Load

VOLTS 115

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

(see Section 11-8).

AMPS 4.5

Rating Data

Rating shows volts and amperes, or

watts required to run equipment.

Amperes x Volts = Watts

Example 1: If a drill uses 4.5 am-

peres at 115 volts, calculate its run-

ning power requirement in 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 Ex-

ample 1, add the individual loads to

calculate total load.

(3 x 200W) + 520 W = 1120 W

The total load applied by the three

flood lamps and drill is 1120 watts.

S-0623

OM-4433 Page 54

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11-5. 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

11-6. 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-4433 Page 55

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11-7. 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

Circular Saw

Table Saw

6-1/2 in

7-1/4 in

8-1/4 in

9 in

500

900

1400

4500

6300

2500

1720

3900

5200

3000

6000

8200

10500

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

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

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

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11-8. Power Required To Start Motor

Single-PhaseInduction Motor Starting Requirements

Motor Start

Code

KVA/HP

6.3

7.1

8.0

9.0

10.0

11.2

12.5

14.0

Motor Start Code

Running Amperage

Motor HP

AC MOTOR

Motor Voltage

VOLTS 230

AMPS 2.5

To find starting amperage:

CODE

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiplyrunning amperage by six to

find starting amperage.

1/4

PHASE 1

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.

(kVA/HP x HP x 1000) / Volts =

Starting Amperage

Example: Calculate starting amper-

age required for a 230 V, 1/4 HP mo-

tor with a motor start code of M.

Volts = 230, HP = 1/4, kVA/HP =

11.2

(11.2 x 1/4 x 1000) / 230 = 12.2A

Starting the motor requires 12.2

amperes.

S-0624

11-9. How Much Power Can Generator Supply?

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.

5 Second Rule

If motor does not start within 5

seconds, turn off power to prevent

motor damage. Motor requires

more power than generator can

supply.

Ref. ST-800 396-A / S-0625

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11-10. Typical Connections To Supply Standby Power

Have only qualified persons

perform these connections

according to all applicable

codes and safety practices.

Fused

Disconnect

Switch

Properly install and ground

this equipment according to

its Owner’s Manual and na-

tional, state, and local codes.

Welding

Generator

Output

Utility

Electrical

Service

Transfer Switch

(If Required)

. Customer-supplied equipment

is required if generator will sup-

ply standby power during

emergencies or power out-

ages.

1 Utility Electrical Service

Essential

Loads

2 Transfer Switch (Double-Throw)

Switch transfers the electrical load

from electric utility service to the

generator. Transfer load back to

electric utility when service is re-

stored.

Install correct switch (customer-

supplied). Switch rating must be

same as or greater than the branch

overcurrent protection.

3 Fused Disconnect Switch

Install correct switch (customer-

supplied) if required by electrical

code.

4 Welding Generator Output

Generator output voltage and wir-

ing must be consistent with regular

(utility) system voltage and wiring.

Connect generator with temporary

or permanent wiring suitable for the

installation.

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 volt-

age and frequency.

5 Essential Loads

Generator output may not meet the

electrical requirements of the prem-

ises. If generator does not produce

enough output to meet all require-

ments, connect only essential

loads (pumps, freezers, heaters,

etc. − See Section 11-4).

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11-11. Selecting Extension Cord (Use Shortest Cord Possible)

Cord Lengths for 120 Volt Loads

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)

600

350 (106)

250 (76)

175 (53)

112 (34)

87 (26)

62 (19)

50 (15)

37 (11)

225 (68)

150 (46)

112 (34)

75 (23)

50 (15)

37 (11)

137 (42)

100 (30)

62 (19)

37 (11)

30 (9)

100 (30)

62 (19)

50 (15)

30 (9)

840

400 (122)

275 (84)

175 (53)

137 (42)

112 (34)

87 (26)

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)

50 (15)

*Conductor size is based on maximum 2% voltage drop

Cord Lengths for 240 Volt Loads

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)

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)

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)

800 (244)

550 (168)

350 (107)

275 (84)

225 (69)

175 (53)

150 (46)

125 (38)

100 (31)

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

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SECTION 12 − PARTS LIST

available unless listed.

Wirng harnesses are listed at

the end of parts section.

4 (Fig.12−5)

101

102

111

103

110 (Fig.12−3)

109

100

108 (Fig.12−2)

104

106

105

107

Figure 12-1. Main Assembly

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80(Fig.12−4)

803 683-F

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 12-1. Main Assembly

Quantity

. . . 1 . . . . HD1 . . . . 168829 . . Transducer, Current 1000a Module Max Open Loop . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . R3 . . . . . 213027 . . Resistor, WW Tap 300 W 40 Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . 217070 . . Bracket, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . Figure 12-5 . . Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Rectifier Mtg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 5 . . . . . . . . . . . . . . 214742 . . Capacitor Assy (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213489 . . . . Bus Bar, Capacitor Bank Negative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213490 . . . . Bus Bar, Capacitor Bank Positive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . C10 . . . . 163535 . . . . Capacitor, Elctlt 16000 Uf 60 Vdc Can 1.75 Dia . . . . . . . . . . . . . . . . . . . 6

. . . 6 . . . . . . . . . . . . . +213488 . . Panel, Engine Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . PC1 . . . . 231705 . . Module, Main Control/Scr Gating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . PC3 . . . . 214770 . . Module, Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . . . . . . . . . . . 215522 . . Bracket, Vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . . Z1 . . . . . 213929 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 192303 . . Angle, Mtg Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 11 . . . . TE1 . . . . 172661 . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 173734 . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 12 . . . . . . . . . . . . . . 213500 . . Brkt, Beam Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . 213602 . . Gasket, Exhaust Outlet Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . . . . . . . . . . . . . 214753 . . Bracket, Holddown Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . 213493 . . Upright, Center Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . 189464 . . Seal, Weather Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . 213501 . . Bracket, Fuel Pump/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 18 . . . . . . . . . . . . . . . . . . . . . . . . Bracket, Fuel Filter Mtg. (Order Thru Engine Manufacturer) . . . . . . . . . . . 1

. . . 19 . . . . . . . . . . . . . . 217687 . . Filter, Fuel Spin−on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . 207721 . . Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 21 . . . . . . . . . . . . . *213858 . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . 212621 . . Pipe, Exhaust Flexible Inlet Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . 183314 . . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 24 . . . . . . . . . . . . . . 212604 . . Baffle, Air Lower Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 25 . . . . . . . . . . . . . . 201528 . . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 26 . . . . . . . . . . . . . . 212605 . . Pipe, Exhaust Blue Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 27 . . . . . . . . . . . . . . 233088 . . Label, Danger Using A Generator Indoors Can Kill You In Minutes . . . . . 1

. . . 28 . . . . . . . . . . . . . +213470 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 049525 . . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

. . . 29 . . . . . . . . . . . . . . 189052 . . Grommet, Plastic Neck Filler Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 30 . . . . . . . . . . . . . . 190198 . . Cap, Tank Screw−on 3.500 In W/Vent W/Lanyard 8” . . . . . . . . . . . . . . . . . 1

. . . 31 . . . . . . . . . . . . . . 222513 . . Label, Warning Falling Equipment Can Cause Serious . . . . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . . . 201851 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 33 . . . . . . . . . . . . . . 214604 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 34 . . . . . . . . . . . . . . 224265 . . Label, Warning Hot Exhaust Parts Do Not Touch . . . . . . . . . . . . . . . . . . . . 1

. . . 35 . . . . . . . . . . . . . . 192041 . . Label, Use Diesel Fuel Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . . . . . . . . . . . . . 213472 . . Keeper, Latch Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . 213471 . . Bracket, Cover Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 38 . . . . . . . . . . . . . . 217387 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 39 . . . . . . . . . . . . . . 213503 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 40 . . . . . . . . . . . . . +212607 . . Shroud, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 41 . . . . . . . . . . . . . . 233256 . . Radiator, W/14# Cap 3 Row Core 1.25 In Inlet/Outlet (Includes) . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 187120 . . . . Cap, Radiator Pressure 14lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 42 . . . . . . . . . . . . . . 212603 . . Baffle, Air Upper Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 43 . . . . . . . . . . . . . +225400 . . Upright, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 44 . . . . . . . . . . . . . . 225412 . . Cover, Radiator Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 45 . . . . . . . . . . . . . . 220295 . . Bracket, Stiffener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 46 . . . . . . . . . . . . . . 190190 . . Tank, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 47 . . . . . . . . . . . . . . 213502 . . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 48 . . . . . . . . . . . . . . 215268 . . Label, Diesel Engine Maintenance Cat 3013c . . . . . . . . . . . . . . . . . . . . . . . 1

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

. . . 49 . . . . . . . . . . . . . . 199592 . . Latch, Paddle Series 20 (Black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 50 . . . . . . . . . . . . . +213487 . . Door, Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 191626 . . Bumper, Door Engine Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 51 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 3

. . . 52 . . . . . . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 53 . . . . . . . . . . . . . . 087341 . . Bumper, Door 1.000 Od X .750 High Rbr 50 Duro W/O . . . . . . . . . . . . . . 2

. . . 54 . . . . . . . . . . . . . . 213486 . . Panel, Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 55 . . . . . . . . . . . . . . 217698 . . Label, Help Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 56 . . . . . . . . . . . . . . 168385 . . Label, Warning Battery Explosion Can Blind . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 57 . . . . . . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 58 . . . . . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦230637 . . Idle, Solenoid Assy (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 59 . . . . . . . . . . . . ♦230828 . . . . Bracket, Mtg Solenoid Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 60 . . . . TS1 . . ♦230634 . . . . Solenoid, Throttle W/4−8.4 Lb Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦198109 . . . . Screw, Shld Stl Sch .250−20 X .437 X .500 Shld . . . . . . . . . . . . . . . . . . . 1

. . . 61 . . . . . . . . . . . . ♦198018 . . . . Linkage, Throttle Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦230830 . . . . Arm, Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 62 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 63 . . . . . . . . . . . . . . 197506 . . Screw, M14−1.5x 30 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . 64 . . . . . . . . . . . . . . 213480 . . Bracket, Mtg Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 65 . . . . . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Split10mm . . . . . . . . . . . . . . . . . . 2

. . . 66 . . . . . . . . . . . . . . 049026 . . Screw, M10−1.5x 25 Hex Hd−pln 8.8 Pln . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 67 . . . . . . . . . . . . . . . . . . . . . . . . Washer, Oil Drain (Order Thru Engine Manufacturer) . . . . . . . . . . . . . . . . . 1

. . . 68 . . . . . . . . . . . . . . 212612 . . Ftg, Adapter Oil Drain Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 199505 . . Hose Assy, Oil Drain 32.000 Lg (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 69 . . . . . . . . . . . . . . 165271 . . . . Valve, Oil Drain 3/8−18 Nptf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 70 . . . . . . . . . . . . . . 176529 . . . . Ftg, Hose Brs Barbed Fem 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . . . 1

. . . 71 . . . . . . . . . . . . . . 113854 . . . . Hose, Sae .500 Id X .780 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Ft.

. . . 72 . . . . . . . . . . . . . . 197448 . . Ftg, Hose Brs Barbed Elbow M 1/2 Tbg X 3/8 Npt . . . . . . . . . . . . . . . . . . . 1

. . . 73 . . . . . . . . . . . . . . 212614 . . Hose, Radiator Lower Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 74 . . . . . . . . . . . . . . 217686 . . Belt, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 75 . . . . . . . . . . . . . . 217651 . . Engine, Perkins (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 212600 . . . . Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *202166 . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 217695 . . Switch, Coolant Temp N.c. 110c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 217696 . . Switch, Lubricating Oil Pressure N.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 76 . . . . . . . . . . . . . . 212613 . . Hose, Radiator Upper Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 77 . . . . . . . . . . . . . . 216811 . . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 78 . . . . . . . . . . . . . . 197613 . . Air Cleaner, Intake 5.250 In (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197675 . . . . Dust Ejector, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . *197676 . . . . Element, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197677 . . . . Cover Assy, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197678 . . . . Body, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . ♦*197679 . . . . Element, Air Cleaner Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 197829 . . . . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 79 . . . . . . . . . . . . . . 212617 . . Hose, Air Intake Cat 3013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 80 . . . . . . . . . . Figure 12-4 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 81 . . . . . . . . . . . . . . 213461 . . Bracket, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 82 . . . . . . . . . . . . . . 213266 . . Mount, Engine/Generator Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 83 . . . . . . . . . . . . . . 212623 . . Tank, Fuel (Includes Fuel Cap And Items Below) . . . . . . . . . . . . . . . . . . . . 1

. . . 84 . . . . . . . . . . . . . . 189908 . . . . Valve, Drain Fuel 180 Deg Zinc Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 85 . . . . . . . . . . . . . . 181572 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 86 . . . . . . . . . . . . . . 124253 . . . . Bushing, Tank Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 87 . . . . . . . . . . . . . . 212611 . . . . Hose, Fuel Stand Pipe W/3/16 In Ftg (Return) . . . . . . . . . . . . . . . . . . . . . 1

. . . 88 . . . . . . . . . . . . . . 212610 . . . . Hose, Fuel Stand Pipe W/5/16 In Ftg (Supply) . . . . . . . . . . . . . . . . . . . . . 1

. . . 89 . . SENDER . . 213265 . . . . Sender, Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-1. Main Assembly (Continued)

. . . . . . . . . . . . . . . . . . . . 172071 . . Clamp, Hose .520 − .605 Clp Dia Slfttng Black . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . 211961 . . Hose, Sae .312 Id X .560 Od X 16.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 213804 . . Hose, Sae .312 Id X .560 Od X 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 191819 . . Hose, Sae .312 Id X .560 Od X 15.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 145054 . . Hose, Sae .187 Id X .410 Od X 26.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 90 . . . . . . . . . . . . . . 213465 . . Bolt, J Stl .312−18 X 7.250 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 91 . . . . . . . . . . . . . . 213466 . . Bracket, Battery Holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 92 . . . . BATT . . . . 146237 . . Battery, Stor 12v 585 Crk 95 Rsv Gp 55 Maint Free . . . . . . . . . . . . . . . . . 1

. . . 93 . . . . . . . . . . . . . . 190207 . . Cable, Bat Pos 45 In Lg No 1 Awg W/Clamp & .406 Rng . . . . . . . . . . . . . 1

. . . 94 . . . . . . . . . . . . . . 213668 . . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 95 . . . . . . . . . . . . . . 213458 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 96 . . . . . . . . . . . . . . 213483 . . Support, Engine Rh Cat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 97 . . . . . . . . . . . . . . 190206 . . Cable, Bat Neg 42 In Lg 2 Awg W/Clamp & .375 Rng . . . . . . . . . . . . . . . . 1

. . . 98 . . . . . . . . . . . . . . 224266 . . Label, Warning Do Not Weld On Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 99 . . . . . . . . . . . . . . 213462 . . Pad, Mtg Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213670 . . Screw, 500−13x2.25 Hex Flange−hd Gr8 Pln Chem/Phys . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . 100 . . . . . . . . . . . . . 213463 . . Spacer/Snubber, Generator Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 101 . . . . . . . . . . . . . 213485 . . Support, Engine Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 102 . . . . . . . . . . . . . 213459 . . Crossmember, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 103 . . . . . . . . . . . . . 213460 . . Crossmember, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213600 . . Screw, 500−13x3.00 Hex Flange−hd Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 071731 . . Washer, Flat .656idx2.250odx.187t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 213464 . . Bracket, Battery Locator (In Base − Not Shown) . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213506 . . Bracket, Hold−Down Fuel Tank (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 104 . . . . . . . . . . . . +226104 . . Upright, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 105 . . . . . . . . . . . . . 233953 . . Label, Warning General Precautionary CSA . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 106 . . . . . . . . . . . . . 216347 . . Label, Rating Card Code 133 (Provide Serial No. When Ordering) . . . . . 1

. . 107 . . . . . . . . . . . . . 220955 . . Panel, Front Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 108 . . . . . . . . . Figure 12-2 . . Front Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 109 . . . . . . . . . . . ♦105370 . . Xfmr, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 110 . . . . . . . . . Figure 12-3 . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . 111 . . . . . . . . . . . . . 213504 . . Tray, Reactor&Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 213491 . . Insulator, Capacitor Bank (Applies To Reactor /Redtifier Tray) . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 215328 . . Kit, Label (Includes Safety And Informational Labels) . . . . . . . . . . . . . . . . . 1

When ordering a component originally displaying a precautionary label, the label should also be ordered.

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.

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available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 684-B

Figure 12-2. Panel, Front w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 108)

. . . 1 . . . . . . . . . . . . . . 097926 . . Knob, Pointer 2.375 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 072590 . . Lock, Shaft Pot .375−32 X .250 Dia Shaft Tall . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . 170391 . . Conn, Circ Ms Protective Cap Size 20 Nylon . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . 190323 . . Boot, Circuit Breaker Clear Hex Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 5 . . . . . . . . . . . . . . 097922 . . Knob, Pointer .875 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Control (Order By Model & Serial No.) . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . PC6 . . . . 229949 . . Circuit Card Assy, Connector/Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . CB7, CB8 . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2

. . . 9 . . . . . . . . . . . . . . 213655 . . Panel, Front Engine/Weld Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-2. Panel, Front w/Components (Continued)

. . . 10 . . . . . . . . . . . . . . 214543 . . Enclosure, Circuit Card Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . . . . . . . . . . . 134201 . . Stand−off Support, Pc Card .312/.375w/Post&lock .43 . . . . . . . . . . . . . . . 4

. . . 12 . . . . PC2 . . . . 214660 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . R1 . . . . . 214760 . . Switch, Rotary 12 Posn 1p 200ma 28vdc W/Resistors . . . . . . . . . . . . . . . 1

. . . 14 . . . . . R2 . . . . . 193118 . . Pot, Cp Flat 1t 2. W 1k Ohm Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . S4 . . . . . 021467 . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . S1 . . . . . 212436 . . Switch, Ignition 4 Position (Includes Knob) . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 17 . . . . . . . . . . . . . . 039047 . . Terminal, Pwr Output Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 18 . . . . . . . . . . . . . . 010381 . . Connector, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 19 . C13, 14, 15 . 128750 . . Capacitor, Cer Disc .1 Uf 500 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 20 . . . . . . . . . . . . . . 209056 . . Cover, Receptacle W/Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 21 . . . . RC11 . . . . 182954 . . Rcpt, Str 3p4w 50a 125/250v Flush Mtg *14−50 . . . . . . . . . . . . . . . . . . . . . 1

. . . 22 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Generator Power (Order By Model & Serial No.) . . . . . . . . . . 1

. . . 23 . . . . . . . . . . . . . . 213509 . . Panel, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 24 . . . RC5,6 . . . 214918 . . Rcpt,Str Dx Grd 2p3w 20a 125v *5−20r (Order By Model & Serial No.)

. . . 24 . . GFCI1, 2 . . 151981 . . Rcpt, Str Dx Grd 2p3w 15/20a 125v *5−20r Gfi (Order By Model & Serial No.)

. . . 25 . . C11, C12 . . 217054 . . Capacitor, Cer Disc .0047 Uf 3000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 2

. . . 26 . . CB4, CB6 . . 093996 . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . . 2

. . . 27 . . . . CB5 . . . . 203026 . . Supplementary Protector, Man Reset 2p 50a 240vac . . . . . . . . . . . . . . . . 1

. . . 28 . . . . GRD . . . . 083030 . . Stud, Brs .250−20 X 1.750 W/Hex Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 29 . . . . . . . . . . . . . . 010915 . . Washer, Flat .257idx0.640odx.031t Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 30 . . . . . . . . . . . . . . 601836 . . Nut, 250−20 .50hex .19h Brs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 31 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Weld Terminal (Order By Model & Serial No.) . . . . . . . . . . . . . 1

. . . 32 . . . . . . . . . . . . . . 181169 . . Spacer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 33 . . . . . . . . . . . . . . 186621 . . Boot, Generic Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 34 . . . . . . . . . . . . . . 180735 . . Washer, Output Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 35 . . . . . . . . . . . . . . 039046 . . Terminal, Pwr Output Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 36 . . FUEL/HM . . 214768 . . Gauge, Fuel Elec/Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 37 . . . . . . . . . . . . . . 021385 . . Boot, Toggle Switch Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

OM-4433 Page 66

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available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 689-D

Figure 12-3. Control Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-3. Control Panel (Figure 12-1 Item 110)

. . . 1 . . . . . . . . . . . . . . 220981 . . Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 129524 . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . . 2

. . . 3 . . . . CR2 . . . . 214876 . . Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . CB1 . . . . 190374 . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . CR1 . . . . 223710 . . Relay, Encl 12vdc Dpst−no 25a 6pin Flange . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 046432 . . Holder, Fuse Mintr .250 X 1.250 Panel Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . . F1 . . . . . 085874 . . Fuse, Mintr Cer Slo−blo 10. Amp 250 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . . R4 . . . . . 217335 . . Resistor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 9 . . . . CR4 . . ♦090104 . . Relay, Encl 12vdc Spst 30a/15vdc 5pin Flange Mtg . . . . . . . . . . . . . . . . . . 1

. . . 10 . . . . CR3 . . . . 197325 . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 11 . . . . SR3 . . ♦035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . SR1, SR2 . . 035704 . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 13 . . . . PC5 . . ♦214761 . . Module, Pull To Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 14 . . CB2, CB3 . . 083432 . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . . 2

. . . 15 . . . . CB9 . . ♦230635 . . Circuit Breaker, Auto Reset 12vdc 8 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

OM-4433 Page 67

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available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 686-B

Figure 12-4. Generator

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-4. Generator (Figure 12-1 Item 80)

. . . 1 . . . ROTOR . . . 212474 . . Rotor, Generator 4 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . 053390 . . . . Bearing, Ball Rdl Sgl Row 1.370 X 2.830 X .6 . . . . . . . . . . . . . . . . . . . . . 1

. . . 3 . . . . . . . . . . . . . . 192600 . . . . Fan, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 4 . . . . . . . . . . . . . . 159918 . . Baffle, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . . . . . . . . . 212126 . . Adapter, Engine Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 6 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6

. . . 7 . . . . . . . . . . . . . . 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6

. . . 8 . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . 6

. . . 9 . . . . . . . . . . . . . . 192686 . . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . 6

. . . 10 . . . . . . . . . . . . . . 212641 . . Stud, Stl .375−16 1.625x 19.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

. . . 11 . . STATOR . . 212470 . . Stator, Generator 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 12 . . . . . . . . . . . . . . 160943 . . Endbell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 13 . . . . . . . . . . . . . . 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . 4

. . . 14 . . . . . . . . . . . . . . 218552 . . Brush, Assembly 2 Pole (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 15 . . . . . . . . . . . . . . 047879 . . . . Bar, Retaining Brushholder 2 Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 16 . . . . . . . . . . . . . . 161306 . . . . Cap, Brushholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 17 . . . . . . . . . . . . . . 126984 . . . . Brush w/Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 18 . . . . . . . . . . . . . . 005614 . . . . Holder, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . 19 . . . . . . . . . . . . . . 125548 . . . . Holder, Brush Elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 20 . . . . . . . . . . . . . . 158832 . . Screw, 010−32x .50 Hex Hd−slt Stl Pld Sq Cone Sems . . . . . . . . . . . . . . 2

When ordering a component originally displaying a precautionary label, the label should also be ordered.

*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-4433 Page 68

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available unless listed.

Wirng harnesses are listed at

the end of parts section.

803 685-A

Figure 12-5. Rectifier Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 12-5. Rectifier Assembly (Figure 12-1 Item 4)

. . . . . . . . . . . . . . . . . . . . 217081 . . Rectifier, Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 1 . . . . . . . . . . . . . . 211984 . . . . Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . MOD1,2,3 . . 218296 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 3 . . MOD4,5,6 . . 218292 . . . . Kit, Module SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 4 . . . . . . . . . . . . . . 212602 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 5 . . . . . . . . . . . . . . 212639 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 6 . . . . . . . . . . . . . . 212601 . . . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 7 . . . . TH1 . . . . 213930 . . . . Thermistor, Ntc 30k Ohm @ 25 Deg C 8.5in Lead . . . . . . . . . . . . . . . . . 1

. . . 8 . . . . C1−6 . . . . 215611 . . . . Capacitor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . 9 . . . C7,8,9 . . . 048420 . . . . Capacitor, Cer Disc .01 Uf 1000 Vdc W/Terms . . . . . . . . . . . . . . . . . . . . 3

. . . 10 . . . . . . . . . . . . . . 217085 . . . . Bus Bar, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 181853 . . Insulator, Screw (For Mounting Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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-4433 Page 69

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(

)

nents separately or as part of the associated wiring harness.

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Wiring Harnesses

. . . . . . . . . . . . . . . . . . . . 231122 . . Harness, Engine (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . S4 . . . . . 021467 . . . . Switch, Tgl Spst 3a 250v Off−none−(On) Spd Term . . . . . . . . . . . . . . . . 1

. . . . . . . . SR1, SR2 . . 035704 . . . . Rectifier, Integ Bridge 40. Amp 800v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . CB1 . . . . 190374 . . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB2, CB3 . . 083432 . . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . 2

. . . . . . . . . . CR3 . . . . 197325 . . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . CR2 . . . . 214876 . .

Relay, Encl 6vdc Spst 35a/14vdc 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . R4 . . . . . 217335 . . . . Resistor Board, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 148850 . . . . Socket, Relay 5 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 212116 . . . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 212117 . . . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . PLG1 . . . . 214932 . . . . Conn, Rect Univ 039 8p/S 2row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

. . . . . . . . . . . . . . . . . . . . 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . For S1 . . . 211292 . . . . Conn, Pack 4p 1row Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . For S1 . . . 211293 . . . . Conn, Pack Terminal Position Assurance(Lock) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 129524 . . . . Term, Frict 250x032 Uninsul Male .130 Stud Mtg 3pr . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 217002 . . Harness, Weld Control (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG2 . . . . 150316 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG9 . . . . 214951 . . . . Conn, Rect Univ 039 6p/S 3row Plug Cable Lkg Seal . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 214934 . . . . Seal, Plug Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . PLG8 . . . . 147992 . . . . Conn, Rect Univ 039 10p/S 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG6 . . . . 193184 . . . . Conn, Rect Cinch 30 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG7 . . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . PLG9 . . . . 215261 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG10 . . . 215262 . . . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 215265 . . . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 215343 . . . . Seal, Plug Deutsch 12−16 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

. . . . . . . . . . PLG5 . . . . 113750 . . . . Conn, Rect Mini 045 4skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 217000 . . . . Cable, Lem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 215340 . . . . Conn, Rect Univ 039 2p/S 1row Rcpt Cable/Pnl Lkg S . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 214933 . . . . Seal, Wire Univ 039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . 214984 . . Harness, Rectifier Cc/Cv (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . PLG11 . . . 193183 . . . . Conn, Rect Cinch 18 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . 207716 . . . . Conn, Faston Mini Polarized 2 Skt G1k1 . . . . . . . . . . . . . . . . . . . . . . . . . 6

. . . . . . . . . . . . . . . . . . . . 207718 . . . . Conn, Faston Mini Polarized 2 Skt G2k2 . . . . . . . . . . . . . . . . . . . . . . . . . 3

. . . . . . . . . . . . . . . . . . . . 217010 . . Harness, Receptacle Auxiliary Power (Includes) . . . . . . . . . . . . . . . . . . 1

. . . . . . . . CB4, CB6 . . 093996 . . . . Supplementary Pro, Man Reset 1p 20a 250vac Fric . . . . . . . . . . . . . . . . 2

OM-4433 Page 70

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Effective January 1, 2007

(Equipment with a serial number preface of “LH” 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, Cables, and

Non-Electronic Controls

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

Canvas Covers

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.

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 delivery date of the

equipment to the original end-user purchaser, and not to exceed

one year after the equipment is shipped to a North American

distributor or eighteen months after the equipment is shipped 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

2. 3 Years — Parts and Labor

Transformer/Rectifier Power Sources

Plasma Arc Cutting Power Sources

Process Controllers

Semi-Automatic and Automatic Wire Feeders

Inverter Power Sources (Unless Otherwise Stated)

Water Coolant Systems (Integrated)

Intellitig

Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the

engine manufacturer.)

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.

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

Motor Driven Guns (w/exception of Spoolmate

Spoolguns)

Positioners and Controllers

Automatic Motion Devices

RFCS Foot Controls

Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES

PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE

REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY

OTHER LEGAL THEORY.

Water Coolant Systems (Non-Integrated)

Flowgauge and Flowmeter Regulators (No Labor)

HF Units

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

Grids

ANY

IMPLIED

WARRANTY,

GUARANTY

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,

Spot Welders

Load Banks

Arc Stud Power Sources & Arc Stud Guns

Racks

Running Gear/Trailers

Plasma Cutting Torches (except APT & SAF

Models)

Field Options

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT

FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED

BY MILLER.

(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.)

Bernard-Branded Mig Guns (No Labor)

Weldcraft-Branded TIG Torches (No Labor)

Subarc Wire Drive Assemblies

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,

4. 6 Months — Batteries

5. 90 Days — Parts

MIG Guns/TIG Torches and Subarc (SAW) Guns

but may vary from province to province.

miller_warr 2007−01

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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

www.millerwelds.com or call 1-800-4-A-Miller

www.MillerWelds.com

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

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