Miller Electric 500Dx R Users Manual Body

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Big Blue 500DX



OM-129 647W

July 1999

Processes

Description

Air Carbon Arc (CAC-A) Cutting

and Gouging

Stick (SMAW) Welding

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Engine Driven Welding Generator

With Optional Equipment:

Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor

to receive the latest full line catalog or

individual catalog sheets. To locate your nearest

distributor call 1-800-4-A-Miller.

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know

you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller products

had to be more than the best they could be. They had to

be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first welding equip-

ment manufacturer in the U.S.A.

to be registered to the ISO 9001

Quality System Standard.

Working as hard as you do −

every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

The following terms are

used interchangeably

throughout this manual:

Stick = SMAW

MIG = GMAW

CALIFORNIA

Proposition 65

Warning

Diesel engine exhaust and

some of its constituents

are known to the State of

California to cause

cancer, birth defects, and

other reproductive harm.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Engine Hazards 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers existant en relation avec le moteur 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Symbols And Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions, Weights, And Operating Angles 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Fuel Consumption 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Duty Cycle And Overheating 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. AC Auxiliary Power 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Volt-Ampere Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Optional AC Power Plant Curves 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Installing Welding Generator 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Installing Exhaust Pipe 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Activating The Dry Charge Battery 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Connecting The Battery 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Engine Prestart Checks 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Connecting To Weld Output Terminals 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Selecting Weld Cable Sizes 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Installing Ether Cylinder (Optional Ether Starting Aid) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Remote A/V Control Receptacle RC3 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Remote 14 Receptacle RC3 Information (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11. Terminal Strip 2T Connections (Optional) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATING THE WELDING GENERATOR 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Standard Controls (See Section 5-2) 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Description Of Standard Controls (See Section 5-1) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Controls For Models With CV Option (See Section 5-4) 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Description Of Controls For Models With CV Option (See Section 5-3) 23. . . . . . . . . . . . . . . . .

SECTION 6 − OPERATING AUXILIARY EQUIPMENT 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. 120 Volt And 240 Volt Duplex Receptacles 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Optional Auxiliary Power Receptacles 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Connecting Optional Auxiliary Power Plant 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Maintenance Label 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Servicing Air Cleaner 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Servicing Fuel And Lubrication Systems 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Adjusting Engine Speed 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Servicing Optional Ether Starting Aid 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Checking And Replacing Alternator Belt 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Resetting Fan Belt Safety Shutdown 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler 34. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-10. Overload Protection For Models With CV Option 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11. Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − RUN-IN PROCEDURE 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Wetstacking 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Run-In Procedure Using Load Bank 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Run-In Procedure Using Resistance Grid 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − AUXILIARY POWER GUIDELINES 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − PARTS LIST 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

WARNING

This product, when used

for welding or cutting,

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.)

WARNING

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 reproductive

harm. Wash hands after

handling.

OM-129 647 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

rom _nd_11/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible

hazards with this procedure! The possible hazards are

shown in the adjoining symbols.

Marks a special safety message.

Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary

actions to avoid the hazards.

1-2. Arc Welding Hazards

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 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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 equipment is a hazard.

Do not touch live electrical parts.

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.

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

there is a danger of falling.

Use AC output ONLY if required for the welding process.

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

unit.

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).

Properly install and ground this equipment according to its

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

Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal

in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

When making input connections, attach proper grounding

conductor first − double-check connections.

Frequently inspect 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.

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

with a separate cable.

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.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

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

or worktable as near the weld as practical.

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.

SIGNIFICANT DC VOLTAGE exists after stopping

engine on inverters.

Stop engine on inverter and discharge input capacitors according

to instructions in Maintenance Section before touching any parts.

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.

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter 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 and

glare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes.

If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

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

Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

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

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

person nearby. Welding fumes and gases can displace air and

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

breathing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying

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

form highly toxic and irritating gases.

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

cadmium plated steel, unless the coating is removed from the

weld area, the area is well ventilated, and if necessary, while

wearing an air-supplied respirator. The coatings and any metals

containing these elements can give off toxic fumes if welded.

OM-129 647 Page 2

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks,

hot workpiece, and hot equipment can cause fires

and burns. Accidental contact of electrode to metal objects can

cause sparks, explosion, overheating, or fire. Check and be sure the

area is safe before doing any welding.

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal.

Do not weld where flying sparks can strike flammable material.

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

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

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

Watch for fire, and keep a fire extinguisher nearby.

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

can cause fire on the hidden side.

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).

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 and fire hazards.

Do not use welder to thaw frozen pipes.

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.

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

from your person before doing any welding.

FLYING METAL can injure eyes.

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

Wear approved safety glasses with side

shields even under your welding helmet.

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.

HOT PARTS can cause severe burns.

Allow cooling period before maintaining.

Wear protective gloves and clothing when

working on a hot engine.

Do not touch hot engine parts or just-welded

parts bare-handed.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

Wear approved ear protection if noise level is

high.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away.

Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat,

mechanical shocks, 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.

Keep cylinders away from any welding or other electrical circuits.

Never drape a welding torch over a gas cylinder.

Never allow a welding electrode to touch any cylinder.

Never weld on a pressurized cylinder − explosion will result.

Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

Turn face away from valve outlet when opening cylinder valve.

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

use or connected for use.

Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

1-3. Engine Hazards

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.

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.

STEAM AND HOT COOLANT can burn.

If possible, check coolant level when engine is

cold to avoid scalding.

Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine

manual).

If the engine is warm, checking is needed, and

there is no overflow tank, follow the next two

statements.

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

Turn cap slightly and let pressure escape slowly before

completely removing cap.

OM-129 647 Page 3

MOVING PARTS can cause injury.

Keep away from fans, belts, and rotors.

Keep all doors, panels, covers, and guards

closed and securely in place.

Stop engine before installing or connecting unit.

Have only qualified people remove guards or covers for maint-

enance 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.

Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

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

components.

BATTERY EXPLOSION can BLIND.

Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

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.

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

BATTERY ACID can BURN SKIN and EYES.

Do not tip battery.

Replace damaged battery.

Flush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

Use equipment outside in open, well-

ventilated areas.

If used in a closed area, vent engine exhaust

outside and away from any building air in-

takes.

ENGINE HEAT can cause fire.

Do not locate unit on, over, or near

combustible surfaces or flammables.

Keep exhaust and exhaust pipes way from

flammables.

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. Additional Symbols For Installation, Operation, And Maintenance

FALLING UNIT can cause injury.

Use lifting eye to lift unit only, NOT running

gear, gas cylinders, trailer, or any other

accessories.

Use equipment of adequate capacity to lift and

support unit.

If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

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 prop-

er face, hand, and body protection.

Sparks can cause fires — keep flammables away.

OVERHEATING can damage motors.

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.

Do not connect 50 or 60 Hertz motors to the 100 Hertz recep-

tacle where applicable.

OVERUSE can cause OVERHEATING.

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.

STATIC (ESD) can damage PC boards.

Put on grounded wrist strap BEFORE

handling boards or parts.

Use proper static-proof bags and boxes to

store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

Use tongue jack or blocks to support weight.

Properly install welding generator onto trailer

according to instructions supplied with trailer.

READ INSTRUCTIONS.

Use only genuine MILLER replacement parts.

Perform engine maintenance and service

according to this manual and the engine

manual.

OM-129 647 Page 4

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and

communications equipment.

Have only qualified persons familiar with

electronic equipment perform this installation.

The user is responsible for having a qualified electrician

promptly correct any interference problem resulting from the

installation.

If notified by the FCC about interference, stop using the

equipment at once.

Have the installation regularly checked and maintained.

Keep high-frequency source doors and panels tightly shut,

keep spark gaps at correct setting, and use grounding and

shielding to minimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

Be sure all equipment in the welding area is

electromagnetically compatible.

To reduce possible interference, keep weld cables as short as

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

Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

Be sure this welding machine is installed and grounded

according to this manual.

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.

1-5. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington,

D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

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

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

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.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from

operator as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-129 647 Page 5

SECTION 1 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

rom _nd_fre 5/97

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure

présente des risques de danger ! Ceux-ci sont identifiés

par des symboles adjacents aux directives.

Identifie un message de sécurité particulier.

Signifie NOTA ; n’est pas relatif à la sécurité.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des

risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN

MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles

et aux directives ci-dessous afin de connaître les mesures à prendre pour

éviter tout danger.

1-2. Dangers relatifs au soudage à l’arc

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

présent manuel pour attirer votre attention et identifier les

risques de danger. Lorsque vous voyez un symbole, soyez

vigilant et suivez les directives mentionnées afin d’éviter tout

danger. Les consignes de sécurité présentées ci-après ne

font que résumer l’information contenue dans les normes de

sécurité énumérées à la section 1-5. 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

particulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut

provoquer une électrocution ou des blessures graves.

L’électrode et le circuit de soudage sont sous tension dès

que l’appareil est sur ON. Le circuit d’entrée et les circuits

internes de l’appareil sont également sous tension à ce

moment-là. En 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.

Ne jamais toucher les pièces électriques sous tension.

Porter des gants et des vêtements de protection secs ne comportant pas

de trous.

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

isolants suffisamment grands pour empêcher le contact physique éventuel

avec la pièce ou la terre.

Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

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 conformément à son

manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

Toujours vérifier la terre du cordon d’alimentation − Vérifier et s’assurer que

le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre

du sectionneur ou que la fiche du cordon est raccordée à une prise

correctement mise à la terre.

En effectuant les raccordements d’entrée fixer d’abord le conducteur de

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

Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas en-

dommagé ou dénudé − remplacer le cordon immédiatement s’il est

endommagé − un câble dénudé peut provoquer une électrocution.

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

Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou

mal épissés.

Ne pas enrouler les câbles autour du corps.

Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct − ne pas utiliser le connecteur de pièce ou le câble de retour.

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

une électrode provenant d’une autre machine.

N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-champ

les pièces endommagées. Entretenir l’appareil conformément à 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.

Le rayonnement de l’arc du procédé de soudage génère

des rayons visibles et invisibles intenses (ultraviolets et

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la

peau. Des étincelles sont projetées pendant le soudage.

LES RAYONS DE L’ARC peuvent pro-

voquer des brûlures dans les yeux et

sur la peau.

Porter un casque de soudage muni d’un écran de filtre approprié pour pro-

téger votre visage et vos yeux pendant le soudage ou pour regarder (voir

ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair et de

l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

Porter des vêtements de protection constitué dans une matière durable, ré-

sistant au feu (laine ou cuir) et une protection des pieds.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation

peut être dangereux pour votre santé.

Eloigner votre tête des fumées. Ne pas respirer les fumées.

À l’interieur, ventiler la zone et/ou utiliser un échappement au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air

homologué.

Lire les spécifications de sécurité des matériaux (MSDSs) et les instruc-

tions du fabricant concernant les métaux, les consommables, les

revêtements, les nettoyants et les dégraisseurs.

Travailler dans un espace fermé seulement s’il est bien ventilé ou en por-

tant 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 souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de

l’arc peuvent réagir en présence de vapeurs et former des gaz hautement

toxiques et irritants.

Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvani-

sé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été

enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si néces-

saire, en portant un respirateur à alimentation d’air. Les revêtements et

tous les métaux renfermant ces éléments peuvent dégager des fumées

toxiques en cas de soudage.

OM-129 647 Page 6

Le soudage effectué sur des conteneurs fermés tels que

des réservoirs, tambours ou des conduites peut provoquer

leur éclatement. Des étincelles peuvent être projetées de

l’arc de soudure. La projection d’étincelles, des pièces chaudes et des

équipements chauds peut provoquer des incendies et des brûlures. Le contact

accidentel de l’électrode avec des objets métalliques peut provoquer des

étincelles, une explosion, un surchauffement ou un incendie. Avant de

commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de

danger.

LE SOUDAGE peut provoquer un in-

cendie ou une explosion.

Se protéger et d’autres personnes de la projection d’étincelles et de métal

chaud.

Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des

substances inflammables.

Déplacer toutes les substances inflammables à une distance de 10,7 m de

l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec

des protections homologués.

Des étincelles et des matériaux chauds du soudage peuvent facilement

passer dans d’autres zones en traversant de petites fissures et des

ouvertures.

Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

Le soudage effectué sur un plafond, plancher, paroi ou séparation peut dé-

clencher un incendie de l’autre côté.

Ne pas effectuer le soudage sur des conteneurs fermés tels que des réser-

voirs, tambours, ou conduites, à moins qu’ils n’aient été préparés

correctement conformément à AWS F4.1 (voir les normes de sécurité).

Brancher le câble sur la pièce le plus près possible de la zone de soudage

pour éviter le transport du courant sur une longue distance par des che-

mins inconnus éventuels en provoquant des risques d’électrocution et

d’incendie.

Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

En cas de non utilisation, enlever la baguette d’électrode du porte-électrode

ou couper le fil à la pointe de contact.

Porter des vêtements de protection dépourvus d’huile tels que des gants

en cuir, une chemise en matériau lourd, des pantalons sans revers, des

chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos poches telles

qu’un allumeur au butane ou des allumettes.

DES PARTICULES VOLANTES

peuvent blesser les yeux.

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 métalliques volan-

tes. Pendant la période de refroidissement des soudures, elles risquent

de projeter du laitier.

Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES ACCUMULATIONS DE GAZ ris-

quent de provoquer des blessures ou

même la mort.

Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

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

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent

provoquer des brûlures graves.

Prévoir une période de refroidissement avant d’effec-

tuer des travaux d’entretien.

Porter des gants et des vêtements de protection pour

travailler sur un moteur chaud.

Ne pas toucher à mains nues les parties chaudes du moteur ni les pièces

récemment soudées.

LE BRUIT peut affecter l’ouïe.

Le bruit des processus et des équipements peut affecter

l’ouïe.

Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez à distance.

Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher

des opérations de soudage à l’arc, de gougeage ou

de soudage par points.

Si des BOUTEILLES sont endomma-

gées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous

haute pression. Si une bouteille est endommagée, elle

peut exploser. Du fait que les bouteilles de gaz font

normalement partie du procédé de soudage, les manipuler

avec précaution.

Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des

chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des

arcs.

Placer les bouteilles debout en les fixant dans un support stationnaire ou

dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

Tenir les bouteilles éloignées des circuits de soudage ou autres circuits

électriques.

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

Une électrode de soudage ne doit jamais entrer en contact avec une bou-

teille.

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.

Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la bouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation

ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz comprimé,

les équipements associés et les publication P-1 CGA énumérées dans les

normes de sécurité.

1-3. Dangers existant en relation avec le moteur

LE CARBURANT MOTEUR peut pro-

voquer un incendie ou une explosion.

Arrêter le moteur avant de vérifier le niveau de carbu-

rant ou de faire le plein.

Ne pas faire le plein en fumant ou proche d’une sour-

ce d’étincelles ou d’une flamme nue.

Ne pas faire le plein de carburant à ras bord; prévoir de l’espace pour son

expansion.

Faire attention de ne pas renverser de carburant. Nettoyer tout carbu-

rant renversé avant de faire démarrer le moteur.

Jeter les chiffons dans un récipient ignifuge.

LA VAPEUR ET LE LIQUIDE DE

REFROIDISSEMENT CHAUD peuvent

provoquer des brûlures.

Il est préférable de vérifier le liquide de

refroidissement une fois le moteur refroidi pour éviter

de se brûler.

Si le moteur est chaud et que le liquide doit être vérifié, opérer comme

suivant :

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

bouchon du radiateur.

Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant

d’enlever le bouchon.

OM-129 647 Page 7

DES ORGANES MOBILES peuvent

provoquer des blessures.

Ne pas approcher les mains des ventilateurs, cour-

roies et autres pièces en mouvement.

Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

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

Demander seulement à un personnel qualifié d’enlever les dispositifs de

sécurité ou les recouvrements pour effectuer, s’il y a lieu, des travaux

d’entretien et de dépannage.

Pour empêcher tout démarrage accidentel pendant les travaux d’entre-

tien, débrancher le câble négatif (−) de batterie de la borne.

Ne pas approcher les mains, cheveux, vêtements lâches et outils des or-

ganes mobiles.

Remettre en place les panneaux ou les dipositifs de protection et fermer

les portes à la fin des travaux d’entretien et avant de faire démarrer le

moteur.

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

en route accidentelle du moteur.

Bloquer le volant moteur pour éviter sa rotation lors d’une intervention

sur le générateur.

L’EXPLOSION DE LA BATTERIE peut

RENDRE AVEUGLE.

Toujours porter une protection faciale, des gants en

caoutchouc et vêtements de protection lors d’une in-

tervention sur la batterie.

Arrêter le moteur avant de débrancher ou de brancher les câbles de

batterie.

Eviter de provoquer des étincelles avec les outils en travaillant sur la

batterie.

Ne pas utiliser le poste de soudage pour charger les batteries ou des vé-

hicules de démarrage rapide.

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

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

lieu.

L’ACIDE DE LA BATTERIE peut pro-

voquer des brûlures dans les YEUX et

sur la PEAU.

Ne pas renverser la batterie.

Remplacer une batterie endommagée.

Rincer immédiatement les yeux et la peau à l’eau.

LES GAZ D’ÈCHAPPEMENT DU

MOTEUR peuvent provoquer des

accidents mortels.

Utiliser l’équipement à l’extérieur dans des zones ou-

vertes et bien ventilées.

En cas d’utilisation dans un endroit fermé évacuer les gaz d’échappe-

ment du moteur vers l’extérieur à distance des entrées d’air dans les bâti-

ments.

LA CHALEUR DU MOTEUR peut pro-

voquer un incendie.

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

té de surfaces inflammables.

Tenir à distance les produits inflammables de

l’échappement.

LES ÉTINCELLES À L’ÉCHAPPEMENT

peuvent provoquer un incendie.

Empêcher les étincelles d’échappement du moteur

de provoquer un incendie.

Utiliser uniquement un pare-étincelles approuvé −

voir codes en vigueur.

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

LA CHUTE DE L’APPAREIL peut

blesser.

Utiliser l’anneau de levage uniquement pour

soulever l’appareil lui-même ; sans chariot, de

bouteilles de gaz, remorque, ou autres accessoires.

Utiliser un équipement de levage de capacité suffi-

sante pour lever l’appareil.

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.

LES ÉTINCELLES VOLANTES ris-

quent de provoquer des blessures.

Porter un écran facial pour protéger le visage et les

yeux.

Affuterr l’électrode au tungstène uniquement à la meuleuse dotée de

protecteurs. Cette manoeuvre est à exécuter dans un endroit sûr lorsque

l’on porte l’équipement homologué de protection du visage, des mains et

du corps.

Les étincelles risquent de causer un incendie − éloigner toute substance

inflammable.

LE SURCHAUFFEMENT peut endom-

mager le moteur électrique.

Arrêter ou déconnecter l’équipement avant de dé-

marrer ou d’arrêter le moteur.

Ne pas laisser tourner le moteur trop lentement sous

risque d’endommager le moteur électrique à cause

d’une tension et d’une fréquence trop faibles.

Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz, s’il y a

lieu.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

Laisser l’équipement refroidir ; respecter le facteur de

marche nominal.

Réduire le courant ou le facteur de marche avant de

poursuivre le soudage.

Ne pas obstruer les passages d’air du poste.

LES CHARGES ÉLECTROSTATIQUES

peuvent endommager les circuits

imprimés.

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.

UNE REMORQUE QUI BASCULE peut

entraîner des blessures.

Utiliser les supports de la remorque ou des blocs

pour soutenir le poids.

Installer convenablement le poste sur la remorque

comme indiqué dans le manuel s’y rapportant.

LIRE LES INSTRUCTIONS.

Utiliser uniquement des pièces de rechange

MILLER.

Effecteur la maintenance et la mise en service

d’après le manuel et celui du moteur.

OM-129 647 Page 8

LE RAYONNEMENT HAUTE FRÉ-

QUENCE (H.F.) risque de provoquer

des interférences.

Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équipements

de radio−navigation et de communication, les

services de sécurité et les ordinateurs.

Demander seulement à des personnes qualifiées familiarisées avec des

équipements électroniques de faire fonctionner l’installation.

L’utilisateur est tenu de faire corriger rapidement par un électricien quali-

fié les interférences résultant de l’installation.

Si le FCC signale des interférences, arrêter immédiatement l’appareil.

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

Maintenir soigneusement fermés les portes et les panneaux des sources

de haute fréquence, maintenir les éclateurs à une distance correcte et

utiliser une terre et et un blindage pour réduire les interférences

éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique

sensible tel que les ordinateurs et l’équipement com-

mandé par ordinateur tel que les robots.

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

électromagnétiquement.

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

ge aussi courts que possible, les grouper, et les poser aussi bas que pos-

sible (ex. par terre).

Veiller à souder à une distance de 100 mètres de tout équipement élec-

tronique sensible.

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

ment à ce mode d’emploi.

En cas d’interférences après avoir pris les mesures précédentes, il in-

combe à l’utilisateur de prendre des mesures supplémentaires telles que

le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de fil-

tres de ligne ou la pose de protecteurs dans la zone de travail.

1-5. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American

Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme

AWS F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Mi-

ami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, de la Compressed Gas Association, 1235 Jefferson Davis High-

way, Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes,

norme CSA W117.2, de l’Association canadienne de normalisation,

vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada

M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-6. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

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 examiné plus de 500 études qui ont été faites pendant une pé-

riode de recherche de 17 ans, un comité spécial ruban bleu du

National Research Council a conclu: “L’accumulation de preuves, sui-

vant le jugement du comité, n’a pas démontré que l’exposition aux

champs magnétiques et champs électriques à haute fréquence repré-

sente un risque à la santé humaine”. Toutefois, des études sont

toujours en cours et les preuves continuent à être examinées. En at-

tendant que les conclusions finales de la recherche soient établies, il

vous serait souhaitable de réduire votre exposition aux champs élec-

tromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

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

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible

de vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il

est alors recommandé de respecter les consignes ci−dessus.

OM-129 647 Page 9

SECTION 2 − DEFINITIONS

2-1. Symbols And Definitions

Stop Engine Start Engine Ether Starting Aid Engine

Do Not Switch

While Welding Battery (Engine) Circuit Breaker Engine Oil

Check Injectors/

Pump Check Valve

Clearance Fuel Protective Earth

(Ground)

Positive Negative Certified/Trained

Mechanic Welding Arc

AAmperes VVolts Panel/Local 14 Remote

On Temperature Output Alternating

Current

Stick (SMAW)

Welding Constant Current

(CC) MIG (GMAW)

Welding Constant Voltage

(CV)

Time hHours sSeconds 1Single Phase

3Three Phase Read Operator’s

Manual

SECTION 3 − SPECIFICATIONS

3-1. Weld, Power, And Engine Specifications

Welding

Mode

Weld

Output

Range

Rated Welding

Output

Maximum

Open-

Circuit

Voltage

Auxiliary Power

Rating Engine Fuel Capacity

CC/DC 45 − 600 A 500 A, 40 Volts DC,

60% Duty Cycle

95 (88 in CC

mode on

units with CV) Single-Phase,

3 kVA/kW, 25 A,

Deutz F3L-912

Air-Cooled,

Three-Cylinder, 23 gal (87 L)

CV/DC

(Optional) 14 − 38 V 400 A, 36 Volts DC,

100% Duty Cycle 48

3 kVA/kW

,

25 A

,

120 V AC, 60 Hz

Three Cylinder

,

41.5 HP Diesel

Engine

23 gal (87 L)

OM-129 647 Page 10

3-2. Dimensions, Weights, And Operating Angles

Dimensions

Height 47-5/8 in (1210 mm)

Width 31-1/4 in (794 mm) L



Depth 60-1/2 in (1537 mm) Engine End Do not exceed operating angles while

runnin

g

or en

g

ine dama

g

e will occur.

A59-1/8 in (1502 mm)

running or engine damage will occur

.

Do not move or operate unit where it

ld ti

B47-1/4 in (1200 mm)

p

could tip.

C43-1/4 in (1099 mm)

D32-3/4 in (832 mm)

E24-15/16 in (633 mm) A

C

F10-1/2 in (267 mm) B

C

D

G6-1/2 in (165 mm)

D

E

17 5°

H2-7/8 in (73 mm)

E

F

17.5°

J29-7/8 in (759 mm)

F

G

20°17.5°

K11/16 in (24 mm) G

H

J

K

20°

20

L21/32 in (17 mm) Dia.

16 Holes

H

J

K

angles_1 3/96

Weight ST-158 699

angles

_

1 3/96

1898 lb (861 kg)

3-3. Fuel Consumption

The curve shows typical fuel use

under weld or power loads.

Ref. ST-047 094-C

OM-129 647 Page 11

3-4. Duty Cycle And Overheating

rduty1 5/95 − SB-089 697-D

Duty Cycle is percentage of 10

minutes that unit can weld at rated

load without overheating.

Exceeding duty cycle can

damage unit and void

warranty.

60% Duty Cycle At 500 Amperes

6 Minutes Welding 4 Minutes Resting

3-5. AC Auxiliary Power

rsb3.1 2/92 − Ref. SB-005 192-C

The ac power curve shows the

auxiliary power in amperes avail-

able at the 120 and 240 volt recep-

tacles.

OM-129 647 Page 12

3-6. Volt-Ampere Curves

ST-183 880-A / ST-186 173-A

The volt-ampere curve shows the

minimum and maximum voltage

and amperage output capabilities

of the welding generator. Curves of

all other settings fall between the

curves shown.

A. CC/DC (Standard)

B. CV/DC (Models With CV Option)

OM-129 647 Page 13

3-7. Optional AC Power Plant Curves

rsb13.1 12/94 - SB-005 185-B / SB-159 101-A

The ac power curves show the

auxiliary power in amperes avail-

able at the single-phase 120/240

volt or three-phase 240 volt

terminals.

A. 7.5 KVA/KW Single-Phase Auxiliary Power Plant (No Weld Load)

B. 10 KVA/KW Three-Phase Auxiliary Power Plant (No Weld Load)

OM-129 647 Page 14

SECTION 4 − INSTALLATION

4-1. Installing Welding Generator

install1 3/96 − Ref. ST-800 652 / Ref. ST-800 477-A / ST-158 936-A / S-0854

1

2

Electrically bond generator frame to

vehicle frame by metal-to-metal

contact.

GND/PE

34

1 Generator Base

2 Metal Vehicle Frame

3 Equipment Grounding

Terminal

4 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

If unit does not have GFCI

receptacles, use GFCI-

protected extension cord.

2

OR

18 in

(460 mm)

18 in

(460 mm)

18 in

(460 mm) 18 in

(460 mm)

18 in

(460 mm)

OR

Movement Airflow Clearance Location

Grounding

OR

Do Not Lift Unit From End

4-2. Installing Exhaust Pipe

Stop engine and let cool.

1/2 in

Tools Needed:

exh_pipe2 4/96 − ST-154 089-A / ST-154 611 / ST-180 933-B

Do not blow exhaust toward

air cleaner or air intake.

Top View

OM-129 647 Page 15

4-3. Activating The Dry Charge Battery

drybatt1 2/96 − S-0886

Remove battery from unit.

1 Eye Protection − Safety

Glasses Or Face Shield

2 Rubber Gloves

3 Vent Caps

4 Sulfuric Acid Electrolyte

(1.265 Specific Gravity)

5 Well

Fill each cell with electrolyte to

bottom of well (maximum).

Do not overfill battery cells.

Wait ten minutes and check elec-

trolyte level. If necessary, add elec-

trolyte to raise to proper level.

Reinstall vent caps.

6 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

maintain proper level.

3

Tools Needed:

1

2

4

6

30 A For 12 Minutes

5 A For 30 Minutes

OR

+

−

5

OM-129 647 Page 16

4-4. Connecting The Battery

1/2 in

−

+

Connect Negative (−)

Cable Last.

ST-153 654-B / ST-180 933-B / S-0756-C

Tools Needed:

4-5. Engine Prestart Checks

Full

1/2 in

(13 mm) Full

Ref. ST-158 633-C

Valve Open

Diesel

Check all fluids daily. Engine must

be cold and on a level surface.

Follow run-in procedure in engine

manual. If unburned fuel and oil

collect in exhaust pipe during run-

in, see Section 9.

1 Fuel

Do not use gasoline. Gaso-

line will damage engine.

Add fresh diesel fuel before start-

ing engine the first time (see main-

tenance label for specifications).

Fill fuel tank up to 1/2 in. (13 mm)

from top to allow room for expan-

sion. Open fuel shut-off valve.

Do not run out of fuel or air enters

fuel system and causes starting

problems. See engine manual to

bleed air from fuel system.

2 Oil

After fueling, check oil with unit on

level surface. If oil is not up to full

mark on dipstick, add oil (see

maintenance label).

To improve cold weather

starting:

Keep battery in good condi-

tion. Store battery in warm

area off concrete surface.

Use fuel formulated for cold

weather (diesel fuel can gel in

cold weather). Contact local

fuel supplier for fuel in-

formation.

Use correct grade oil for cold

weather.

OM-129 647 Page 17

4-6. Connecting To Weld Output Terminals

ST-158 700

Open left side door.

1 Bracket

Route cables through bracket.

2 Positive (+) Weld Output

Terminal

3 Negative (−) Weld Output

Terminal

For Stick welding Direct Current

Electrode Positive (DCEP), con-

nect work cable to − terminal and

electrode holder cable to +

terminal.

For Direct Current Electrode Neg-

ative (DCEN), reverse cable

connections.

If equipped with optional polarity

switch, connect electrode holder

cable to Electrode (−) terminal and

work cable to Work (+) terminal.

For MIG and FCAW welding with

CV option, connect work cable to

(−) terminal and wire feeder cable

to (+) terminal

Close door.

Tools Needed:

3

Left Side

2

1

3/4 in

4-7. Selecting Weld Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding

Welding

Amperes

100 ft (30 m) Or Less 150 ft

(45 m) 200 ft

(60 m) 250 ft

(70 m) 300 ft

(90 m) 350 ft

(105 m) 400 ft

(120 m)

Amperes

10 − 60%

Duty Cycle 60 − 100%

Duty Cycle 10 − 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

*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. Contact your

distributor for the mm2 equivalent weld cable sizes. S-0007-E

OM-129 647 Page 18

ether1 7/96 − ST-153 382-A / ST-180 933-B

Stop engine.

Improper handling or expo-

sure to ether can harm your

health. Follow manufactur-

er’s safety instructions on

cylinder.

Do not use Ether Starting

Aid while engine is running.

Open side door(s).

1 Ether Cylinder

2 Nozzle

Remove cover and clean cylinder

nozzle.

3 Clamp

4 Fitting

5 Cap

6 Valve

Remove cap and clean fitting.

Install cylinder on fitting. Tighten

clamp.

After installing cylinder, wait at

least 10 minutes before using

to let ether particles settle and

prevent atomizer plugging.

Put cap on fitting when cylinder is

removed.

1

2

3

4

6

5

4-8. Installing Ether Cylinder (Optional Ether Starting Aid)

4-9. Remote A/V Control Receptacle RC3

Ref. ST-154 862-A / ST-048 720-K

1 Remote A/V Receptacle RC3

Connect optional remote control to

RC3 (see Section 5-2).

OR

1

OM-129 647 Page 19

4-10. Remote 14 Receptacle RC3 Information (Optional)

Socket* Socket Information

AJ

B

KI

A24 volts ac. Protected by circuit

breaker CB4.

BI

CLNH

DMG

BContact closure to A completes 24

volts ac contactor control circuit.

DMG

EFI115 volts ac. Protected by circuit

breaker CB3.

JContact closure to I completes 115

volts ac contactor control circuit.

OR

GCircuit common for 24 and 115

volts ac circuits.

OR C 0 to +10 volts dc output to remote

control from min to max of Amper-

age/Voltage control R1.

A/V

DRemote control circuit common.

Ref. ST-800 862-B

A/V

E0 to +10 volts dc input command

signal from remote control.

Ref

.

ST 800 862 B

KChassis common.

*The remaining sockets are not used.

4-11. Terminal Strip 2T Connections (Optional)

Ref. ST-800 862-B / Ref. ST-185 316

Stop engine.

If remote control plug does not fit in

receptacle RC3, wire cord directly

to terminal strip 2T.

Do not connect to Remote

14 receptacle RC3 and ter-

minal strip 2T at the same

time. Use only one remote

control method.

Open right side door.

1 Cover

2 Terminal Strip 2T

Connect leads to 2T using terminal

information shown in Section 4-10.

Reinstall cover. Close door.

Tools Needed:

1

2

OM-129 647 Page 20

SECTION 5 − OPERATING THE WELDING GENERATOR

5-1. Standard Controls (See Section 5-2)

1

10

2 3

11 9 8 7 6 5 4

12

ST-158 630-B / Ref. ST-158 631 / ST-180 933-B

OM-129 647 Page 21

5-2. Description Of Standard Controls (See Section 5-1)

This unit has a max OCV control circuit

that resets the Amperage/Voltage Con-

trol to maximum when the arc breaks.

When an arc is struck, weld output con-

trol returns to the front panel or remote

control setting. The Amperage/voltage

Control adjusts amperage only when

welding and does not adjust open-circuit

voltage.

1 Ampere Range Switch

Use switch to select one of five ampere

ranges.

For most welding applications, use lowest

amperage range possible to help prevent arc

outages.

Do not switch under load.

2 Amperage/Voltage Control

Control adjusts amperage within range se-

lected by Ampere Range switch. Weld output

would be 223 A DC with controls set as

shown (50% of 125 to 320 A).

3 Remote A/V Control Receptacle And

Switch

Connect optional remote control to RC3 (See

Section 4-9). Use switch to select front panel

or remote amperage control (see example

below).

4 Manual Stop Control

5 Engine Start Button

6 Ether Starting Aid Switch (Optional)

Push switch up and release while cranking

engine to release ether.

Do not use Ether if engine is running.

To Start: Press button and use Ether switch

(if necessary). Release button when engine

starts.

Do not crank engine while engine is turning.

To Stop: Pull control out and hold. Release

control when engine stops.

7 DC Ammeter (Optional)

8 DC Voltmeter (Optional)

9 Oil Pressure Warning Light

Light goes off if oil pressure is too low.

If light goes off, stop engine and

check oil level.

10 Battery Charging Warning Light

Light goes on when battery is not charging.

If light goes on, stop engine and

check engine belt.

11 Engine Hour Meter

12 Polarity Switch (Optional)

S-0774 / Ref. ST-180 933-B

Example: Combination Remote Amperage Control

In Example:

Range = 125 to 320 A

Percentage Of Range = 50%

Max = 223 A DC (50% of 125 to 320)

Adjust Optional Remote ControlSet Switches Set Range Set Percentage

Max (223 A DC)

Min (100 A DC)

OM-129 647 Page 22

5-3. Controls For Models With CV Option (See Section 5-4)

1

9

2

10 8 7 6 5 4 3

11

ST-158 630-B / Ref. ST-158 631 / Ref. ST-185 762-B / S-185 440

12

13

14

OM-129 647 Page 23

5-4. Description Of Controls For Models With CV Option (See Section 5-3)

This unit has a max OCV control circuit

that resets Amperage/Voltage Control

R1 to maximum when the arc breaks.

When an arc is struck, weld output con-

trol returns to the R1 front panel or com-

bination front panel/remote control

setting. The Amperage/Voltage control

adjusts amperage only when constant

current (CC) welding and does not ad-

just open-circuit voltage. The max OCV

control circuit does not function when

constant voltage (CV) welding.

1 Ampere Range Switch

Do not switch under load.

Use switch to select one of five ampere

ranges. Use the lower four ranges for CC

welding. Use the highest range for CV/DC

welding.

For most welding applications, use lowest

amperage range possible to help prevent arc

outages.

2 Amperage/Voltage Control

With CC/CV switch in CC position, use con-

trol to adjust amperage within range selected

by Ampere Ranges switch. With switch in CV

position, use control to adjust voltage.

Weld output would be 223 A DC with

amperage controls set as shown (50% of 125

to 320 A).

3 Manual Stop Control

4 Engine Start Button

5 Ether Starting Aid Switch (Optional)

Push switch up and release while cranking

engine to release ether.

Do not use Ether if engine is running.

To Start: Press button and use Ether switch

(if necessary). Release button when engine

starts.

Do not crank engine while engine is turning.

To Stop: Pull control out and hold. Release

control when engine stops.

6 DC Ammeter (Optional)

7 DC Voltmeter (Optional)

8 Oil Pressure Warning Light

Light goes off if oil pressure is too low.

If light goes off, stop engine and

check oil level.

9 Battery Charging Warning Light

Light goes on when battery is not charging.

If light goes on, stop engine and

check engine belt.

10 Engine Hour Meter

11 Polarity Switch (Optional)

12 Constant Current/Constant Voltage

(CC/CV) Switch

Use switch to select type of weld output. Use

CC for Stick (SMAW) welding. Use CV for

wire feed processes (MIG, FCAW). If using

CV, place Ampere Range switch in maxi-

mum position.

13 Output/Contactor Switch

Weld output terminals are energized

when Output/Contactor switch is On

and engine is running

Use switch to control remote contactor con-

nected to Remote 14 receptacle RC3 or ter-

minal strip 2T.

For weld output, place switch in the On posi-

tion. Open-circuit voltage is present at the

weld output terminals whenever engine is

running.

For remote output control, place switch in

Remote position. Open-circuit voltage is

present at the weld output terminals when

remote contactor switch is closed.

14 Amperage/Voltage Control Switch

Use switch to select front panel or remote

amperage and voltage adjustment.

For front panel control, place switch in Panel

position. For remote control, place switch in

Remote position and connect remote control

to Remote 14 receptacle RC3 or terminal

strip 2T.

S-185 440 / Ref. ST-185 762-B / S-0774

Min

Max

Set Switches Adjust Remote ControlSet Range Set Percentage

Example: Combination Remote Amperage Control In Example:

Mode = CC

Range = 125 to 320 A DC

Percentage Of Range = 50%

Min = 125 A DC

Max = 223 A DC

(50% of 125 to 320)

(223 A DC)

(125 A DC)

OM-129 647 Page 24

SECTION 6 − OPERATING AUXILIARY EQUIPMENT

6-1. 120 Volt And 240 Volt Duplex Receptacles

Ref. ST-180 933-B

3

2

If unit does not have GFCI

receptacles, use GFCI-pro-

tected extension cord.

1 120 V 15 A AC Receptacle

RC2

2 240 V 15 A AC Receptacle

RC1

Receptacles supply 60 Hz single-

phase power at weld/power speed.

3 Circuit Breakers CB1 And

CB2

CB1 and CB2 protect RC1 and

RC2 from overload. If CB1 or CB2

opens, RC1 and one half of RC2

does not work. 120 volts may still

be present at RC1. Press button to

reset breaker.

If a circuit breaker continues to

open, contact Factory Autho-

rized Service Agent.

Maximum output from each duplex

receptacle is 1.8 kVA/kW, and 3

kVA/kW from all receptacles.

Auxiliary power is not affected

by weld output.

EXAMPLE: If 10 A is drawn from

RC1, only 5 A is available at RC2:

(240 V x 10 A) + (120 V x 5 A) = 3.0

kVA/kW

1

OM-129 647 Page 25

6-2. Optional Auxiliary Power Receptacles

Ref. ST-180 933-B / Ref. ST-182 266

Auxiliary power is not affected

by weld output.

If a circuit breaker continues to

open, contact Factory Autho-

rized Service Agent.

GFCI Receptacle Option

1 120 V 15 A AC GFCI

Receptacle GFCI1

Auxiliary power output and circuit

breaker protection is the same as

standard receptacles (see Section

6-1).

If a ground fault is detected, GFCI

Reset button pops out and

receptacle does not work. Check

for faulty tools plugged in

receptacle. Press button to reset.

At least once a month, run en-

gine at weld/power speed and

press test button to verify

GFCI is working properly.

Australian And South African

Receptacle Options

2 240 V 10 A AC Australian

Receptacle RC1

3 240 Volt 13 A AC South

African Receptacle RC1

RC1 supplies 60 Hz single-phase

power at weld/power speed. Maxi-

mum output from receptacle is 3

kVA/kW.

4 Circuit Breaker CB1

CB1 protects RC1 from overload. If

CB1 opens, RC1 does not work.

Press button to reset breaker.

British Receptacle Option

5 240 Volt 13 A AC British

Receptacles RC1 And RC2

RC1 and RC2 supply 60 Hz single-

phase power at weld/power speed.

Maximum combined output from

both receptacles is 3 kVA/kW.

6 Circuit Breaker CB1

CB1 protects RC1 and RC2 from

overload. If CB1 opens, the recep-

tacles do not work. Press button to

reset breaker.

2

4

5

1

43

6

OM-129 647 Page 26

6-3. Connecting Optional Auxiliary Power Plant

Ref. S-180 187-A

Stop engine.

Power and weld outputs are

live at the same time. Discon-

nect or insulate unused

cables.

Have qualified person install

according to circuit diagram and

Auxiliary Power Guidelines Booklet

(M176 712).

Remove junction box cover.

1 Lead 93

2 Lead 92

3 Lead 91

4 Lead 90 (Neutral)

5 Lead 42 (Circuit Grounding

Lead)

Lead 42 connects to front panel

Ground stud.

6 Grounding Terminal

7 Jumper Lead 42

8 Isolated Neutral Terminal

Jumper 42 is connected to lead 90

at factory. Jumper 42 may be dis-

connected from neutral to meet

applicable electrical codes.

9 User-Supplied Leads

10 Load Terminals

Connect leads to terminals.

11 Fuses F1, F2, And F3

F1, F2, and F3 protect each load

line from overload.

Set Engine Control switch to

Run when using auxiliary

power.

4

5

78

9

6

10 11

Tools Needed:

93

91

90

92

240V

120V

120V

240V

240V

240V

1 3

Volts

Amps

KVA/KW

Single

120/240

31

7.5

Three

240

24

10

60 HzFrequency

Engine Speed

Max. Fuse Size 35 Amperes

1850 RPM

AC Phase

1 Phase

3

Output

Lead 42 connects to GROUND stud on front of

unit.

Jumper 42 is connected to 90 at factory.

F3

F2

F1

1

2

3

78

OM-129 647 Page 27

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

Follow the storage procedure in the engine owner’s manual if the unit will not be

used for an extended period.

NOTE

Recycle

engine

fluids.

Stop engine before maintaining.

See also Engine Manual and Maintenance Label.

Service engine more often if used in severe

conditions.

* To be done by Factory Authorized Service Agent.

8 h

Check Fluid

Levels. See

Section 4-5.

Wipe

Up

Spills.

Drain Water

From Fuel

System.

OIL

Full

FUEL

WATER

50 h

Clean Air Filter.

See Section 7-3.

Clean And

Tighten

Weld

Terminals.

100 h

Clean And

Tighten

Battery

Connections.

Change Oil. See

Section 7-4.

Change Oil

Filter. See

Section 7-4.

250 h200 h

Check And

Clean Spark

Arrestor. See

Section 7-9.

Replace

Unreadable

Labels.

500 h

Repair

Or

Replace

Cracked

Cables.

1000 h

Blow Out Or

Vacuum Inside.

During Heavy

Service,

Clean Monthly.

OR Drain Sludge

From Fuel

Tank. See

Section 7-4.

FUEL

SLUDGE

Service Welding

Generator Brushes

And Slip Rings.

Service More Often

In Dirty Conditions.*

Change Fuel

Filters. See

Section 7-4.

Check

Valve

Clearance.*

1/2 in.

(13 mm) Check Belt

Tension. See

Section 7-7.

OM-129 647 Page 28

7-2. Maintenance Label

DEUTZ F3L912 DIESEL ENGINE

Check

Recommended Oil API Service Classification CD/CE (or better). . .

Oil Change & Filter dirty conditions 100 hours or less. . . . . . . . . . . .

normal conditions 125-150 hours. . . . . . .

Oil Filter MILLER 064 677, Deutz 117-4418, Fram PH6923. . . . . . . . . . . .

Oil Capacity 8.5 qt (8 L) or 9 qt (8.5 L) with filter change. . . . . . . .

+

S-181 642-B

Spark Arrestor Inspection And Service 250 operating hours −. . . . . . . . . . see Owner’s Manual

Fuel Capacity 23 gal (87 L). . . . . . .

Fuel Grade 1-D or 2-D Cetane No. 45 min.. . . . . . . . .

Secondary

Fuel Filter MILLER 064 686, Deutz 117-4423, Fram P4102. . . . . . . . . .

Primary Fuel Filter/

Water Separator MILLER 062 342, Fram P1107. . . . .

Fill filter with clean fuel before installing − read instructions on filter.

Engine RPM − No Load

Weld 1850. . . . . . . . . . . .

Air Filter Service 50 hours or less − see Owner’s Manual. . . . .

Air Filter Element MILLER 020 319, Donaldson P181052,. . . . Fram CAK 253

Alternator Belt Gates 7425, Deutz 0223−5179. . . . . . .

Blower Belt MILLER 064 690, Deutz 223-5531, Gates N7500. . . . . . . . .

Avoid recirculation of air from hot air exit to blower intake.

Have only trained technician maintain injection pump and injectors. AIR,

WATER, or GASOLINE will harm the injection system. If engine has run

out of fuel or fuel filter is changed, bleeding of air may be required.

Check engine manual for proper procedure.

Diesel

See Engine Manual for complete engine care.

Give Engine Specification and Serial Number when ordering parts.

daily.

Battery BCI Group 31. . . . . . . . . . . . .

Cranking Performance at 0°F (-18°C) 800 Amps. . . . .

Valve Clearance − Cold

Intake 0.006 in (0.15 mm). . .

Exhaust 0.006 in (0.15 mm).

Injectors should be checked annually.

30 °C

20

10

0

−10

−20

−30

−40

°F 86

77

68

59

50

41

32

23

14

5

−4

−13

−22

−31

−40

5W/30 (Synthetic)

10W/30

40

10W/40

15W/30

15W/40

30

20W/20

10W

**

*Only with engine

oil preheating

OM-129 647 Page 29

7-3. Servicing Air Cleaner

aircleaner1 4/96 − ST-153 929-B / ST-153 585 / Ref. ST-180 933-B / Ref. S-0698-B

Stop engine.

Do not run engine without air

cleaner or with dirty element.

Clean or replace element if dirty or

damaged. Replace element yearly

or after six cleanings.

1 Dust Cap

2 Baffle

3 Element

4 Plastic Fins

5 Housing

To clean air filter:

Wipe off cap and housing. Remove

cap and dump out dust. Wipe dust

from inside cap and housing with

damp cloth. Remove element and

reinstall cap.

Do not clean housing with air

hose.

Clean element with compressed air

only. Keep nozzle at least 1 in (25

mm) from inside of element. Max.

air pressure: 100 psi (690 kPa). Do

not remove plastic fins. Replace

element if it has holes or damaged

gaskets.

Reinstall element and cap (cap

arrows pointing up).

1235 4

Blow Inspect

OM-129 647 Page 30

7-4. Servicing Fuel And Lubrication Systems

Ref. ST-158 633-C / Ref. ST-180 933-B

Stop engine and let cool.

1 Oil Filter

2 Oil Drain Plug

3 Oil Drain Hose (Optional)

4 Oil Fill Cap

5 Primary Fuel Filter (Fuel/

Water Separator)

6 Petcock

7 Secondary Fuel Filter

8 Fuel Shutoff Valve

9 Fuel Line

10 Sludge Drain Plug

To change oil and filter:

See engine manual.

To drain water from fuel system:

Open primary fuel filter petcock

and drain water into metal contain-

er. Close petcock when water-free

fuel flows.

To replace primary fuel filter:

Close shutoff valve and turn filter

counterclockwise. Remove filter.

Apply thin coat of fuel to gasket on

new filter. Install new filter and turn

clockwise. Open shutoff valve.

Bleed air from fuel system accord-

ing to engine manual.

Inspect fuel line, and replace if

cracked or worn.

To replace secondary fuel filter:

See engine manual.

To drain sludge from fuel tank:

Put metal container under drain,

and remove sludge drain plug. Re-

install plug when done.

After servicing, start engine

and check for fuel leaks.

Stop engine, tighten con-

nections as necessary, and

wipe up spilled fuel.

Close doors.

3/8, 7/16, 3/4 in

5

10

6

8

7

9

2

1

4

Under Left Side

Of Fuel Tank

Valve Open

Tools Needed:

2

3

OM-129 647 Page 31

7-5. Adjusting Engine Speed

ST-045 768-B

Engine speed is factory set and

should not require adjustment. Af-

ter tuning engine, check engine

speed with tachometer. See table

for proper no load speed. If neces-

sary, adjust speed as follows:

1 Plastic Cap

2 High Speed Stop Screw

3 Lock Nut

Remove plastic cap from screw.

Loosen nut. Turn screw out (to-

ward front of engine) several turns.

4 Linkage

5 Lock Nuts

Loosen nuts. Start engine and

move linkage until engine runs at

weld/power speed. Tighten nuts.

Stop engine.

6 Speed Control Lever

Turn screw in until screw touches

lever. Tighten lock nut on screw

and reinstall plastic cap.

Close side door.

1

3/8 in

243

5

Right Side

6

RPM

1850

Tools Needed:

Engine Speed

(No Load)

Weld/Power

7-6. Servicing Optional Ether Starting Aid

ether2 7/96 − ST-153 382-A / Ref. ST-180 933-B / S-0692

Stop engine.

Improper handling or expo-

sure to ether can harm your

health. Follow manufactur-

er’s safety instructions on

cylinder.

If engine does not start in cold

weather, check ether cylinder as

follows:

Remove cylinder from valve.

1 Ether Cylinder

2 Valve

3 Scale

Weigh cylinder to see if it is empty.

Be sure atomizer is not plugged

and valve fitting is clean.

Replace cylinder according to

Section 4-8.

1

2

15 oz33 oz

(935 g) (425 g)

3

Full Empty

OM-129 647 Page 32

7-7. Checking And Replacing Alternator Belt

ST-158 632 / Ref. ST-180 933-B

Stop engine.

To check belt tension:

Remove rear panel.

1 Alternator V-Belt

2 Crank Pulley

3 Alternator Pulley

Place straight edge along top of

pulleys. Pull down belt as far as it

will go, then measure distance

from belt to straight edge.

If measurement is less than 1/2 in

(13 mm), belt is okay. If not okay,

adjust belt tension.

To adjust belt tension:

4 Hex Nuts (2)

5 Alternator Bracket

Loosen nuts. Pivot alternator until

belt is tight. Tighten nuts. Recheck

tightness of belt. Readjust if

necessary.

Replace belt if damaged or

cracked.

To replace belt:

Loosen hex nuts and pivot alterna-

tor clockwise. Remove belt.

Install new belt, pivot alternator un-

til belt is tight, and tighten nuts. Re-

check tightness of belt after run-

ning engine 15 minutes.

Reinstall rear panel.

1

1/2, 11/16 in

1/2 in

(13 mm)

Max

4

3

5

2

Tools Needed:

OM-129 647 Page 33

7-8. Resetting Fan Belt Safety Shutdown

ST-158 715 / Ref. ST-158 632 / Ref. ST-180 933-B

Stop engine.

1 Cooling Fan V-Belt

See engine manual to replace or

tighten belt.

If belt breaks or becomes loose,

safety shutdown stops engine.

Correct problem, then reset safety

shutdown as follows:

2 Rod

3 Stop

4 Bracket

5 Handle

Pull handle towards front of unit un-

til stop snaps in position behind

bracket.

Close door.

1

3/8 in

Right Side

5

2

3

4

Tools Needed:

Pull Handle To

Reset Shutdown

OM-129 647 Page 34

7-9. Inspecting And Cleaning Optional Spark Arrestor Muffler

ST-800 633-B / Ref. ST-180 933-B

Stop engine and let cool.

1 Spark Arrestor Muffler

2 Cleanout Plug

Remove plug and remove any dirt

covering cleanout hole.

3 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.

Tools Needed:

3

21

3/8 in

7-10. Overload Protection For Models With CV Option

1 Circuit Breaker CB3

CB3 protects the 115 volt ac output

to Remote receptacle RC3 and ter-

minal strip 2T.

If CB3 opens, the 115 volt ac output

stops.

2 Circuit Breaker CB4

CB4 protects the 24 volts ac output

to Remote receptacle RC3 and ter-

minal strip 2T.

If CB3 opens, the 24 volt ac output

stops.

Press button to reset circuit

breaker. If a breaker continues

to open, contact Factory Au-

thorized Service Agent.

1

ST-800 862-A / ST-148 404

2

OM-129 647 Page 35

7-11. Troubleshooting

A. Welding

Trouble Remedy

No weld output. Check position of Ampere Range switch.

Check position of optional polarity switch.

Disconnect equipment from auxiliary power receptacles during start-up.

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote con-

trol to Remote A/V Control receptacle RC3 (see Sections 4-9 and 5-1).

Check and secure connections to Remote A/V Control receptacle RC3 (see Section 4-9).

Place optional Output/Contactor Control switch in On position, or place switch in Remote position and

connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T (see Sections 4-10

and 4-11).

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

optional field current regulator board PC1.

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.

Check Ampere Range switch connections and contacts.

High or low weld output. Check engine speed, and adjust if necessary (see Section 7-5).

Check optional CC/CV switch position.

Low open-circuit voltage. Check engine speed, and adjust if necessary (see Section 7-5).

Check optional CC/CV switch position.

Have Factory Authorized Service Agent check optional field current regulator board PC1 and CV

regulator board PC2.

Maximum weld output only in each

ampere range. Have Factory Authorized Service Agent check Amperage/Voltage control R1, capacitor C8, diode D8,

integrated rectifier SR4, control relay CR2, and optional CV regulator board PC2.

Wire feeder does not work (models with

CV option). Reset circuit breaker CB3 and/or CB4 (see Section 7-10).

Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-10 and

4-11).

Repair or replace wire feeder.

No amperage control (or voltage control

on models with CV option). Place A/V Control switch in correct position.

Check connections to optional Remote 14 receptacle RC3 and terminal strip 2T (see Sections 4-10 and

4-11).

Repair or replace remote control device.

Have Factory Authorized Service Agent check optional CV regulator board PC2.

Low CV weld output (models with CV

option). Set Ampere Range switch to highest range.

Min or max CV weld output only (models

with CV option). Check position of Amperage/voltage control and Amperage/Voltage Control switch.

OM-129 647 Page 36

Trouble Remedy

Repair or replace remote control device.

Have Factory Authorized Service Agent check optional CV regulator board PC2.

B. Auxiliary Power

Trouble Remedy

No output at auxiliary power

receptacles. Reset receptacle circuit breakers.

Have Factory Authorized Service Agent check brushes and slip rings, and optional field current regula-

tor board PC1.

High or low output at auxiliary power

receptacles. Check engine speed, and adjust if necessary (see Section 7-5).

No or low output at optional auxiliary

power plant. Check connections to auxiliary power plant (see Section 6-3).

Check engine speed, and adjust if necessary (see Section 7-5).

Place A/V Control switch in Panel position, or place switch in Remote position and connect remote con-

trol to Remote A/V Control receptacle RC3 (see Sections 4-9 and 5-1).

Check fuses F1, F2, and F3 and replace as necessary (see Section 6-3).

Set optional remote control at maximum (see Section 4-9 or 4-10).

Place optional Output/Contactor Control switch in On position, or place switch in Remote position and

connect remote contactor to optional Remote 14 receptacle RC3 or terminal strip 2T (see Sections 4-10

and 4-11).

Place optional CC/CV switch in CC position (see Section 5-3).

Have Factory Authorized Service Agent check brushes and slip rings, and optional field current regula-

tor board PC1.

High output at optional auxiliary power

plant. Check engine speed, and adjust if necessary (see Section 7-5).

Have Factory Authorized Service Agent check optional field current regulator board PC1.

C. Engine

Trouble Remedy

Engine does not start. Check fuel level (see Section 4-5).

Open fuel valve (see Section 4-5).

Check battery and replace if necessary.

Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken

or loose (see Section 7-8).

Check engine Start button and replace if necessary.

Check engine charging system according to engine manual.

See engine manual.

Engine suddenly stops. Check blower fan V-belt according to engine manual. Safety shutdown stops engine if belt is broken

or loose (see Section 7-8).

See engine manual.

Battery discharges between uses. Clean top of battery with baking soda and water solution; rinse with clear water.

Recharge or replace battery if necessary.

OM-129 647 Page 37

Trouble Remedy

Periodically recharge battery (approximately every 3 months).

Engine uses oil during run-in period;

wetstacking occurs. Dry engine (see Section 9).

OM-129 647 Page 38

Notes

OM-129 647 Page 39

SECTION 8 − ELECTRICAL DIAGRAMS

180 941-A

Figure 8-1. Circuit Diagram For Welding Generator (Standard Models)

OM-129 647 Page 40

Figure 8-2. Circuit Diagram For Welding Generator (Models With CV Option)

OM-129 647 Page 41

184 954-C

OM-129 647 Page 42

SECTION 9 − RUN-IN PROCEDURE

run_in1 6/96

9-1. Wetstacking

1 Welding Generator

Run diesel engines near rated

output during run-in period to prop-

erly seat piston rings and prevent

wetstacking. See nameplate or

rating label to find rated output.

 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 dur-

ing run-in.

2 Engine Exhaust Pipe

Wetstacking is unburned fuel and

oil in the exhaust pipe and occurs

during run-in if the engine is run too

long at light load or idle rpm.

If exhaust pipe is coated with a

wet, black, tar-like substance, dry

the engine using one of the follow-

ing run-in procedures.

See the engine manual for addi-

tional engine run-in information.

1

2

OM-129 647 Page 43

9-2. Run-In Procedure Using Load Bank

S-0683

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

1 Load Bank

Turn all load bank switches Off. If

needed, connect load bank to 115

volts ac wall receptacle or genera-

tor auxiliary power receptacle.

2 Welding Generator

Place A/V range switch in maxi-

mum position, A/V control in mini-

mum position, and Output Selector

switch (if present) in either DC

position.

3 Weld Cables

Connect load bank to generator

weld output terminals using proper

size weld cables with correct

connectors. Observe correct

polarity.

Start engine and run for several

minutes.

Set load bank switches and then

adjust generator A/V control so

load equals rated generator output

(see nameplate).

Check generator and load bank

meters after first five minutes then

every fifteen minutes to be sure

generator is loaded properly.

Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum) 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.

4 Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

2

3

4

1

OM-129 647 Page 44

9-3. Run-In Procedure Using Resistance Grid

S-0684

Stop engine.

Do not touch hot exhaust

pipe, engine parts, or load

bank/grid.

Keep exhaust and pipe away

from flammables.

1 Resistance Grid

Use grid sized for generator rated

output.

Turn Off grid.

2 Welding Generator

Place A/V range switch in maxi-

mum position, A/V control in mini-

mum position, and Output Selector

switch (if present) in either DC

position.

3 Weld Cables

Connect grid to generator weld

output terminals using proper size

weld cables with correct connec-

tors (polarity is not important).

4 Voltmeter

5 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 adjust

generator A/V control so load

equals rated generator output (see

nameplate).

Check generator and meters after

first five minutes then every fifteen

minutes to be sure generator is

loaded properly.

Check oil level frequently dur-

ing run-in; add oil if needed.

After one hour (minimum), 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.

6 Engine Exhaust Pipe

Repeat procedure if wetstacking is

present.

1

3

2

5

6

+

4

OM-129 647 Page 45

SECTION 10 − AUXILIARY POWER GUIDELINES

10-1. Selecting Equipment

aux_pwr 2/99 − Ref. ST-159 730 / ST-800 577

1 Auxiliary Power Receptacles

− Neutral Bonded To Frame

2 3-Prong Plug From Case

Grounded Equipment

3 2-Prong Plug From Double

Insulated Equipment

OR

2

Be sure equipment

has this symbol

and/or wording.

3

1

10-2. Grounding Generator To Truck Or Trailer Frame

S-0854

1 Generator Base

2 Metal Vehicle Frame

3 Equipment Grounding

Terminal

4 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

If unit does not have GFCI

receptacles, use GFCI-pro-

tected extension cord.

OR

1

2

Electrically bond generator

frame to vehicle frame by

metal-to-metal contact.

GND/PE

2

3 4

OM-129 647 Page 46

10-3. Grounding When Supplying Building Systems

ST-800 576-B

1 Equipment Grounding

Terminal

2 Grounding Cable

Use #10 AWG or larger insulated

copper wire.

3 Ground Device

Ground generator to system

earth ground if supplying

power to a premises (home,

shop, farm) wiring system.

GND/PE

1 2

Use ground device as stated

in electrical codes.

23

10-4. How Much Power Does Equipment Require?

S-0623

1 Resistive Load

A light bulb is a resistive load and

requires a constant amount of

power.

2 Non-Resistive Load

Equipment with a motor is a non-

resistive load and requires approx-

imately six times more power while

starting the motor than when run-

ning (see Section 10-8).

3 Rating Data

Rating shows volts and amperes,

or watts required to run equipment.

VOLTS 115

4.5

60

AMPS

Hz

1

2

3

3

EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running 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 Example 1,

add the individual loads to calculate total load.

The total load applied by the three flood lamps and drill is 1120 watts.

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

AMPERES x VOLTS = WATTS

OM-129 647 Page 47

10-5. Approximate Power Requirements For Industrial Motors

Industrial Motors Rating Starting Watts Running Watts

Split Phase 1/8 HP 800 300

1/6 HP 1225 500

1/4 HP 1600 600

1/3 HP 2100 700

1/2 HP 3175 875

Capacitor Start-Induction Run 1/3 HP 2020 720

1/2 HP 3075 975

3/4 HP 4500 1400

1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000

5 HP 23300 6000

7-1/2 HP 35000 8000

10 HP 46700 10700

Fan Duty 1/8 HP 1000 400

1/6 HP 1400 550

1/4 HP 1850 650

1/3 HP 2400 800

1/2 HP 3500 1100

10-6. Approximate Power Requirements For Farm/Home Equipment

Farm/Home Equipment Rating Starting Watts Running Watts

Stock Tank De-Icer 1000 1000

Grain Cleaner 1/4 HP 1650 650

Portable Conveyor 1/2 HP 3400 1000

Grain Elevator 3/4 HP 4400 1400

Milk Cooler 2900 1100

Milker (Vacuum Pump) 2 HP 10500 2800

FARM DUTY MOTORS 1/3 HP 1720 720

Std. (e.g. Conveyors, 1/2 HP 2575 975

Feed Augers, Air 3/4 HP 4500 1400

Compressors) 1 HP 6100 1600

1-1/2 HP 8200 2200

2 HP 10550 2850

3 HP 15900 3900

5 HP 23300 6800

High Torque (e.g. Barn 1-1/2 HP 8100 2000

Cleaners, Silo Unloaders, 5 HP 23300 6000

Silo Hoists, Bunk Feeders) 7-1/2 HP 35000 8000

10 HP 46700 10700

3-1/2 cu. ft. Mixer 1/2 HP 3300 1000

High Pressure 1.8 Gal/Min 500 PSI 3150 950

Washer 2 gal/min 550 PSI 4500 1400

2 gal/min 700 PSI 6100 1600

Refrigerator or Freezer 3100 800

Shallow Well Pump 1/3 HP 2150 750

1/2 HP 3100 1000

Sump Pump 1/3 HP 2100 800

1/2 HP 3200 1050

OM-129 647 Page 48

10-7. Approximate Power Requirements For Contractor Equipment

Contractor Rating Starting Watts Running Watts

Hand Drill 1/4 in 350 350

3/8 in 400 400

1/2 in 600 600

Circular Saw 6-1/2 in 500 500

7-1/4 in 900 900

8-1/4 in 1400 1400

Table Saw 9 in 4500 1500

10 in 6300 1800

Band Saw 14 in 2500 1100

Bench Grinder 6 in 1720 720

8 in 3900 1400

10 in 5200 1600

Air Compressor 1/2 HP 3000 1000

1 HP 6000 1500

1-1/2 HP 8200 2200

2 HP 10500 2800

Electric Chain Saw 1-1/2 HP, 12 in 1100 1100

2 HP, 14 in 1100 1100

Electric Trimmer Standard 9 in 350 350

Heavy Duty 12 in 500 500

Electric Cultivator 1/3 HP 2100 700

Elec. Hedge Trimmer 18 in 400 400

Flood Lights HID 125 100

Metal Halide 313 250

Mercury 1000

Sodium 1400

Vapor 1250 1000

Submersible Pump 400 gph 600 200

Centrifugal Pump 900 gph 900 500

Floor Polisher 3/4 HP, 16 in 4500 1400

1 HP, 20 in 6100 1600

High Pressure Washer 1/2 HP 3150 950

3/4 HP 4500 1400

1 HP 6100 1600

55 gal Drum Mixer 1/4 HP 1900 700

Wet & Dry Vac 1.7 HP 900 900

2-1/2 HP 1300 1300

OM-129 647 Page 49

10-8. Power Required To Start Motor

S-0624

1 Motor Start Code

2 Running Amperage

3 Motor HP

4 Motor Voltage

To find starting amperage:

Step 1: Find code and use table to

find kVA/HP. If code is not listed,

multiply running amperage by six

to find starting amperage.

Step 2: Find Motor HP and Volts.

Step 3: Determine starting amper-

age (see example).

Welding generator amperage out-

put must be at least twice the

motor’s running amperage.

VOLTS AMPS

HP

230 2.5

1/4

Hz

PHASE

CODE 60

1

M

AC MOTOR

12

3

4

Single-Phase Induction Motor Starting Requirements

Motor Start

Code GHJ K LMNP

KVA/HP 6.3 7.1 8.0 9.0 10.0 11.2 12.5 14.0

EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4

HP motor with a motor start code of M.

Starting the motor requires 12.2 amperes.

11.2 x 1/4 x 1000

230 = 12.2 A

kVA/HP x HP x 1000

VOLTS = STARTING AMPERAGE

Volts = 230 HP = 1/4 Using Table, Code M results in kVA/HP = 11.2

10-9. How Much Power Can Generator Supply?

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

1 Limit Load To 90% Of

Generator Output

Always start non-resistive (motor)

loads in order from largest to

smallest, and add resistive loads

last.

2 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.

1

2

OM-129 647 Page 50

10-10. Typical Connections To Supply Standby Power

S-0405-A

1 Power Company Service

Meter

2 Main and Branch Overcurrent

Protection

3 Double-Pole, Double-Throw

Transfer Switch

Obtain and install correct switch.

Switch rating must be same as or

greater than the branch overcur-

rent protection.

4 Circuit Breakers or Fused

Disconnect Switch

Obtain and install correct circuit

breakers or switch.

5 Extension Cord

Select as shown in Section 10-11.

6 Generator Connections

Connect terminals or plug of ade-

quate amperage capacity to cord.

Follow all applicable codes and

safety practices.

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.

7 Load Connections

Customer-supplied equipment is required if

generator is to supply standby power during

emergencies or power outages.

120/240 Volt

60 Hz

Three-Wire

Service

240 V

120 V

120 V

Neutral

240 V

120 V

120 V

120/240 Volt

Single-Phase

Three-Wire

Generator Output

Connection Ground

F1

or

CB

240 V

120 V

120 V

Load

1

23

6

74

5

Item 4 is not necessary if circuit

protection is already present in

welding generator auxiliary

power output circuit.

OM-129 647 Page 51

10-11. 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) 4 6 8 10 12 14

5 600 350 (106) 225 (68) 137 (42) 100 (30)

7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)

10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)

15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)

20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9)

25 3000 175 (53) 112 (34) 62 (19) 37 (11)

30 3600 150 (46) 87 (26) 50 (15) 37 (11)

35 4200 125 (38) 75 (23) 50 (15)

40 4800 112 (34) 62 (19) 37 (11)

45 5400 100 (30) 62 (19)

50 6000 87 (26) 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) 4 6 8 10 12 14

5 1200 700 (213) 450 (137) 225 (84) 200 (61)

7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)

10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)

15 3600 600 (183) 350 (107) 225 (69) 150 (46) 75 (23) 60 (18)

20 4800 450 (137) 275 (84) 175 (53) 100 (31) 60 (18)

25 6000 350 (107) 225 (69) 125 (38) 75 (23)

30 7000 300 (91) 175 (53) 100 (31) 75 (23)

35 8400 250 (76) 150 (46) 100 (31)

40 9600 225 (69) 125 (38) 75 (23)

45 10,800 200 (61) 125 (38)

50 12,000 175 (53) 100 (31)

*Conductor size is based on maximum 2% voltage drop

OM-129 647 Page 52

SECTION 11 − PARTS LIST

1

3

2

45

6

7

6

8

9

10

6

711

12

13

14

15

16

17

18

19

20

21

22

23

676710

24

25 26

70

69

66

65

64

74

75

76

77

78

79

80

81

82

83

84

85

86

Fig 11-5

87

Fig 11−6

&Fig 11-7

88

89

90

91

92

93

Fig 11-2

96

97

98

99

100

101

94 95

Hardware is common and

not available unless listed.

Figure 11-1. Main Assembly

OM-129 647 Page 53

ST-048 455-AA

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

46

47

48

49

50

45

51

52

53

55 54

56

57

59

60

61

62

63

64

65

66

67

68

Fig 11-3

69

70

71

72

73

58

102

OM-129 647 Page 54

Figure 11-1. Main Assembly

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

1 134 771 PLUG, protective .640sq 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 184 675 TANK, fuel 23gal (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 182 022 CAP, fuel large 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 020 185 FITTING, pipe brs elb st 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 053 525 FITTING, brs barbed M 5/16tbg x 1/8NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 172 071 CLAMP, hose .520-.605clp dia slfttng 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 134 835 HOSE, SAE .312 ID x .560 OD (order by ft) 6ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 097 507 STRIP, rbr adh back .125 x 1.000 x 20.500 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 010 314 VALVE, shut-off fuel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 039 599 FITTING, brs barbed M 5/16tbg x 1/4NPT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 +048 227 UPRIGHT, base front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 ♦134 903 FUSE BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+♦134 902 COVER, fuse box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦179 637 LABEL, warning auxiliary power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦026 947 STAND-OFF, insulator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦149 541 HOLDER, fuse crtg 60A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*♦089 585 FUSE, crtg 35A 250V 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦604 102 CONNECTOR, clamp cable 1.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦048 489 CLAMP, nyl 1.000dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 170 689 FRAME, mtg reactor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 170 617 UPRIGHT, base center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 017 479 SEAL, weather lift eye 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 108 081 TERMINAL PROTECTOR, battery post mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 182 276 CABLE, bat pos 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 118 644 HOLD DOWN, battery 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 032 453 CABLE, bat neg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 BAT 012 724 BATTERY, 12V 95A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 010 460 STUD, stl .312-18 x 10.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 083 859 BRACKET, mtg fuel filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 083 553 BASE, filter fuel w/adapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 145 282 FITTING, hose brs barbed elb M 5/16tbg x 1/4NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 062 342 SEPARATOR, fuel filter & water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 116 707 SUPPORT, front engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 010 875 CLAMP, muffler 2.000dia U 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 105 734 PIPE, muffler ext elb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 176 232 BAFFLE, air muffler exhaust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 048 216 BRACKET, mtg breather 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 087 341 BUMPER, door 1.000 OD x .750 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 004 130 BRACKET, support door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 +091 160 DOOR, LH side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168 385 LABEL, warning battery explosion can blind 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 181 642 LABEL, diesel engine maintenance 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 +105 909 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 035 968 WASHER, flat rbr 3.625 ID x 5.875 OD x .062thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195 869 CABLE TIE, 0-17.500 weather resistant 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 108 487 LABEL, warning falling equipment etc 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 048 206 PANEL, end engine 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 +106 411 DOOR, RH side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

089 343 RIVET, nyl .250dia x 1.000 lg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 158 610 LABEL, warning electric shock and moving parts 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 087 336 LATCH, door 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 023 313 CLAMP, hose 3.250-3.000clp dia slfttng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 177 323 HOSE, air cleaner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 010 863 CLAMP, hose 2.062−3.000clp dia slfttng 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165 785 HOSE, air cleaner 2.500 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 045 657 AIR CLEANER, intake (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 021 115 BAND, mtg air cleaner 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 *020 319 ELEMENT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 021 117 WING NUT ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 021 114 CLAMP ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 021 116 CAP, dust 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

004 115 BAFFLE, dust cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 048 213 BAFFLE, air intake 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 LEVER, trip shutdown (included w/engine − see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-129 647 Page 55

Figure 11-1. Main Assembly (Continued)

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

53 SPRING, (included w/engine − see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 181 634 ENGINE, diesel electric (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 087 371 ROD, shutdown 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 070 661 ROD, speed control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604 393 NUT, speed push-on type .187 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 S5 151 969 SWITCH, pressure oil 4psi NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 ♦047 361 FITTING, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 ♦089 351 FITTING, pipe brs plug hexhd 1/2NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 ♦008 114 HOSE, oil w/fittings 17.500 lg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 ♦047 234 BOLT, banjo 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦047 235 WASHER, oil seal copper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 127 994 BALL JOINT, .250-28 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 162 740 STUD, stl .250-28 x 45.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

032 878 CLAMP, stl cush .500dia x .406mtg hole (used on wiring harness) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

64 083 476 TUBING, nprn .875 ID x 2.500 OD x 2.000 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 071 730 TUBING, stl .875 OD x 12ga wall x 2.375 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 071 890 RETAINER, mount engine/generator 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 SHUNT 030 084 SHUNT, meter 500MV 600A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 Fig 11-3 GENERATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 071 731 WASHER, flat stl .656 ID x 2.250 OD x .187thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 601 945 SCREW, cap stl hexhd .625-18 x 4.000 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 176 236 BAFFLE, air outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 CLAMP, muffler (included w/engine − see engine parts list) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 105 733 PIPE, muffler extension elb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 165 739 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 R2 030 060 RESISTOR, WW adj 375W 20 ohm (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 170 681 STRIP, mtg resistor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 R3 128 862 RESISTOR, WW adj 375W 50 ohm (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 ♦186 008 INSULATION, terminal strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 2T ♦038 601 BLOCK, term 30A 9P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 ♦184 499 BRACKET, mtg terminal strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG21 ♦168 071 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 603 107 HOSE, nprn slit bk .156 ID x .343 OD (order by ft) 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 053 967 INSULATION, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 TE1/TE4 038 621 BLOCK, term 30A 4P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 620 LINK, jumper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 081 499 BRACKET, mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 010 146 CLAMP, nyl .625clp dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 Fig 11-5 CV-3 CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 Fig 11-6 PANEL, mtg components (CC/CV model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 Fig 11-7 PANEL, mtg components (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 +182 171 PANEL, front lower (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 +♦185 826 PANEL, front lower (CC/CV model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 Z1 169 424 REACTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 134 792 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 083 030 STUD, brs .250-20 x 1.750 grounding 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 601 836 NUT, brs hex .250-20 jam hvy grounding 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 019 603 KNOB, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94 Fig 11-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 108 127 BRACKET, mtg terminal pwr output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 ♦088 951 BRACKET, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

96 Pos 039 047 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

97 Neg 039 046 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

98 ♦091 067 SWITCH, polarity 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦059 773 HANDLE, switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 605 288 FITTING, pipe galv plug sq hd .250NPT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 070 010 BOLT, J stl .250-20 x 2.750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 088 696 STRAP, hold down fuel tank 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045 161 KIT, label 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 ♦192 197 BRACKET, mounting 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.

OM-129 647 Page 56

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ST-048 457-N

2Fig 11-4

5

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15

Hardware is common and

not available unless listed.

Figure 11-2. Panel, Front w/Components (CC Model Illustrated)

OM-129 647 Page 57

Figure 11-2. Panel, Front w/Components (Fig 11-1 Item 94)

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

1 154 292 PANEL, front upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 S3 171 878 SWITCH, range (Fig 11-4) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 R1 605 960 RHEOSTAT, WW 300W 34 ohm (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3R1♦072 462 POTENTIOMETER, C std sft 1/T 2W 1000 ohm (CV/CC model) 1. . . . . . . . . . . . . . . . . . . .

4 011 609 SWITCH, tgl SPDT 15A 125VAC (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 032 897 RECEPTACLE, twlk grd 2P3W 15A 125V (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A Arrow Hart 5965V. . . . . . . . . . . . . . . . . . . .

6 CB1,2 139 266 CIRCUIT BREAKER, man reset 1P 15A 250VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 GFCI 1 ♦168 068 RECEPTACLE, str dx grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 RC2 170 901 RECEPTACLE, str dx grd 2P3W 125V (top) (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . .

8 RC1 604 103 RECEPTACLE, str dx grd 2P3W 15A 250V (bottom) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170 493 PLATE, ident receptacle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

025 234 PLUG, str grd 2P3W 15A 250V Arrow Hart 5666V. . . . . . . . . . . . . . . . . . . .

9 PB1 046 433 SWITCH, PB MC NO w/black cap 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 180 904 PLATE, ident control rating (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ♦185 763 PLATE, ident control rating (CC/CV model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 088 731 BUSHING, snap-in nyl .375 ID x .500mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 021 385 BOOT, toggle switch lever 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 148 723 KNOB, pointer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 ♦046 652 METER, amp DC 50MV 0-600 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 ♦046 654 METER, volt DC 0-100 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦003 645 BUS BAR, shunt/sec 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦145 626 BRACKET, mtg shunt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 HM 145 247 METER, hour 10-24VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 082 790 LENS, light green 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 082 789 LENS, light red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 PL1,2 *048 155 BULB, incand flg base 12V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 082 788 HOLDER, indicator light 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 019 754 HANDLE, switch range 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 NAMEPLATE, (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL

*Recommended Spare Parts.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-129 647 Page 58

Figure 11-3. Generator

SD-048 456-E

Hardware is common and

not available unless listed.

1

2

45

64

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10

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OM-129 647 Page 59

FIgure 11-3. Generator (Fig 11-1 Item 68)

Description Quantity

Part

No.

Dia.

Mkgs.

Item

No.

1 106 426 INSULATOR 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 106 440 BUS BAR, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 SR3 106 427 DIODE ASSEMBLY, reverse polarity (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 C4,6 048 420 CAPACITOR, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C2 106 641 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 D2,4,6 037 957 DIODE, rect 275A 300V RP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 106 425 INSULATOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 182 170 BAFFLE, air rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 173 066 BRACKET, mtg brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 048 202 BAFFLE, air diodes 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 018 614 BRUSH SET, (consisting of) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 *151 299 BRUSH, contact 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 600 270 HOLDER, brush 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 152 044 CAP, brushholder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 013 367 LABEL, warning moving parts can cause serious injury 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 +169 423 STATOR, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 +♦170 496 STATOR, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 039 207 BAFFLE, air gen 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 083 751 ROTOR, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 024 617 RING, retaining external 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 053 390 BEARING, ball 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 083 748 FAN, rotor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 044 374 STATOR, excitor (CC model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 ♦180 684 STATOR, excitor (CC/CV model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 173 068 ENDBELL, gen (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 143 220 O-RING, 2.859 ID x .139CS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 106 424 BARREL, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 SR3 106 430 DIODE ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 C5,7 048 420 CAPACITOR, rectifier 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C3 106 641 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 106 425 INSULATOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 D1,3,5 037 956 DIODE, rect 275A 300V SP 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 VR1,R4 046 819 SUPPRESSOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.

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

♦Part of 042 890 Optional 10/7.5kVA 240/120V Auxiliary Power.

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-129 647 Page 60

Figure 11-4. Switch, Range (Fig 11-2 Item 2)

Description Quantity

Part

No.

171 878

Item

No. Dia.

Mkgs.

1 114 235 BRACKET, mtg switch range (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 010 671 SPRING, ext .312 OD x .042 wire x 1.875 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 017 428 LOCATOR, quadrant switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 S10 172 245 SWITCH, micro 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 170 677 BOOT, switch lim plunger seal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 171 854 CONTACT BOARD, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 172 701 CONTACT, movable switch (consisting of) 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 011 025 SPRING, pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 011 010 CONTACT, switch copper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 011 009 CONTACT, switch bronze 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 171 856 SPACER, contact .250thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 011 007 SPRING, pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 011 018 CONTACT, stationary 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 172 702 CONTACT, stationary switch (consisting of) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 011 018 CONTACT, stationary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 171 856 SPACER, contact .250thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 011 095 CONTACT BOARD, stationary switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 011 019 CONTACT BOARD, movable switch 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 011 012 SHIM, guide contact board 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 011 013 GUIDE, contact board movable switch 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

910 11

12

13

14

15

16

17181920

8

15

10 9

ST-145 879-B

1

23

6

ST-145 878-A

Includes

Item 8

7

4

5

Hardware is common and

not available unless listed.

Figure 11-4. Switch, Range

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-129 647 Page 61

Figure 11-5. Control Box CC/CV (Figure 11-1 Item 86) (Optional)

Description Quantity

Part

No.

Item

No. Dia.

Mkgs.

1 605 321 NUT, .468-32 brs blk 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 S6 011 611 SWITCH, tgl DPDT 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 S8,9 011 609 SWITCH, tgl SPDT 15A 125V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 601 836 NUT, .250-20 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 010 915 WASHER, flat 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 083 030 STUD, brs .250-20 x 1.750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 185 778 CV CONTROL BOX 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 RC20 147 663 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 RC21 168 071 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 RC22 158 466 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 SR2 097 353 DIODE/SCR BRIDGE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PC1 185 746 CIRCUIT CARD ASSEMBLY, field 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 RC1 114 064 CONNECTOR, rect univ 84 15 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 PLG1 135 275 CONNECTOR & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 134 201 STAND-OFF, support PC card 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 PC2 185 747 CIRCUIT CARD ASSEMBLY, voltage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 RC1 115 092 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 PC3 150 415 CIRCUIT CARD ASSEMBLY, CONNECTOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 185 761 COVER, CV control box 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 PLG3-5 165 668 CONNECTOR & PINS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 CB3,4 083 432 CIRCUIT BREAKER, man reset 1P 10A 250VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 RC3 143 976 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 039 885 CONNECTOR, circ MS protective 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 147 195 NUT, .375-27 nyl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 021 385 BOOT, tgl switch 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-801 850

1

2

3

45

6

7

8

9

10

11 12

13

14

15

16

17

18

20

4

5

4

5

21

22

23

24

25

19

Hardware is common and

not available unless listed.

Figure 11-5. Control Box CC/CV (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-129 647 Page 62

Figure 11-6. Panel, Mtg Components (CC/CV Model)

(Figure 11-1 Item 87)

Description Quantity

Part

No.

Item

No. Dia.

Mkgs.

1 R2 185 748 RESISTOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SR1,4 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 D8 192 307 KIT, diode w/washers 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R3 128 862 RESISTOR, WW adj 375W 50 ohm w/mtg bkt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 601 836 NUT, brs 250-20 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 134 201 STAND-OFF SUPPORT, PC card 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 185 187 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 3T 185 189 BLOCK, terminal 15A 3P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 083 030 STUD, brs .250-20 x 1.750 hex collar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 010 913 WASHER, flat brs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 1T 038 639 BLOCK, terminal 30A 6P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 164 617 CLIP, wiring 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 D1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 C8 170 674 CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 R6 030 844 RESISTOR, WW fxd 25W 25 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 605 741 CLIP, mtg resistor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 CR1,2 044 588 RELAY, encl 12VDC 3PDT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

ST-801 851

2

34

2

5

6

789

10

511

14

13 12

12

15

16

17

Hardware is common and

not available unless listed.

Figure 11-6. Panel, Mtg Components (CC/CV Model)

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-129 647 Page 63

Figure 11-7. Panel, Mtg Components (CC Model)

(Figure 11-1 Item 87)

Description Quantity

Part

No.

Item

No. Dia.

Mkgs.

1 170 672 PANEL, mtg components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 R6 030 844 RESISTOR, WW fxd 25W 250 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 605 741 CLIP, mtg resistor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 R5 128 862 RESISTOR, WW adj 375W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SR1,2,4 035 704 RECTIFIER, integ 40A 800V 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 2T 038 621 TERMINAL BLOCK, 30A 4P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 CR2 044 588 RELAY, encl 12VDC 3PDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 D1 189 701 DIODE/CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 D8 192 307 KIT, diode w/washers 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C8 170 674 CAPACITOR BOARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ST-801 852

1

2

34

5

6

7

8

9

10

Hardware is common and

not available unless listed.

Figure 11-7. Panel, Mtg Components (CC Model)

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.

Warranty Questions?

Call

1-800-4-A-MILLER

for your local

Miller distributor.

miller_warr 7/99

Your distributor also gives

you ...

Service

You always get the fast,

reliable response you

need. Most replacement

parts can be in your

hands in 24 hours.

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.

Effective January 1, 1999

(Equipment with a serial number preface of KK" or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

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.

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.

Miller shall honor warranty claims on warranted equipment

listed below in the event of such a failure within the warranty

time periods. All warranty time periods start on the date that

the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American

distributor or eighteen months after the equipment is sent to an

International distributor.

1. 5 Years Parts − 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by

the engine manufacturer.)

3. 1 Year — Parts and Labor

* Motor Driven Guns (w/exception of Spoolmate

185)

* Process Controllers

* Positioners and Controllers

* Automatic Motion Devices

* Robots

* RFCS Foot Controls

* IHPS Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Maxstar 140

* Spot Welders

* Load Banks

* SDX Transformers

* Miller Cyclomatic Equipment

* Running Gear/Trailers

* Plasma Cutting Torches (except APT, ZIPCUT &

PLAZCUT Models)

* Field Options

(NOTE: Field options are covered under True

Blue® for the remaining warranty period of the

product they are installed in, or for a minimum of

one year — whichever is greater.)

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting

Torches

* Remote Controls

* Accessory Kits

* Replacement Parts (No labor)

* Spoolmate 185

Miller’s True Blue® Limited Warranty shall not apply to:

1. 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.

2. Consumable components; such as contact tips, cutting

nozzles, contactors, brushes, slip rings, relays or parts

that fail due to normal wear.

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.

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.

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 OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT), WHETHER BASED ON CONTRACT, TORT OR

ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN

AND ANY IMPLIED WARRANTY, GUARANTY OR

REPRESENTATION AS TO PERFORMANCE, AND ANY

REMEDY FOR BREACH OF CONTRACT TORT OR ANY

OTHER LEGAL THEORY WHICH, BUT FOR THIS

PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE

OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL

EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND

DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long

an implied warranty lasts, or the exclusion of incidental,

indirect, special or consequential damages, so the above

limitation or exclusion may not apply to you. This warranty

provides specific legal rights, and other rights may be

available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain

additional warranties or remedies other than as stated herein,

and to the extent that they may not be waived, the limitations

and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may

be available, but may vary from province to province.

PRINTED IN USA © 1999 Miller Electric Mfg. Co. 7/99

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters −

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

To locate distributor nearest you call

1-800-4-A-Miller.

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Contact the Delivering Carrier for:

For assistance in filing or settling claims,

contact your distributor and/or equipment

manufacturer’s Transportation Department.

Resources Available

Owner’s Record

File a claim for loss or damage during

shipment.